Plastic molding apparatus and method with shaper module

ABSTRACT

An injection molding apparatus comprises a support base and a mold carrier removably mounted to the support base. The mold carrier includes a mounting plate with attachment features for engaging the support base. A mold with two mold plates is slidably mounted to the mounting  5  plate. A clamp is operable to move the plates between open and closed positions. In the closed position, the plates abut one another. In the open position, the plates are spaced apart for removing molded articles.

RELATED APPLICATIONS

This application claims priority from U.S. Provisional patentapplication 62/724,790, filed Aug. 30, 2018, U.S. Provisional PatentApplication 62/7770,785, filed Nov. 22, 2018, U.S. Provisional patentapplication no 62/856,833, filed Jun. 4, 2019, and U.S. Provisionalpatent application no. 62/866,059, filed Jun. 25, 2019, the disclosuresof which are incorporated herein by reference.

FIELD

This relates to production of plastic articles, and more particularly,to methods and apparatus for operation of molds.

BACKGROUND

Typical plastic molding machines, such as injection molding and blowmolding machines, are large and heavy and are installed permanently at aproduction facility. Mold components are fixed to platens, which areoperated by a fixed press, which may be mechanically or hydraulicallyactuated. Set up of a machine to produce molded articles with a specificmold is complex and both time and labour-intensive.

In an injection molding machine, a mold typically comprises two halves,with one half, referred to as the cavity, defining the outer surface ofan article to be molded, and the other half, referred to as the core,defining the inner surface of the article to be molded. To removearticles, molds must be opened through a long stroke to provideclearance between the mold and cavity, and a separate moving structurereferred to as a stripper plate is extended to push articles off thecore.

SUMMARY

An example apparatus for operating a mold having a cavity assembly and acore that cooperatively define a mold for molding of plastic articlescomprises: a clamping assembly operable to move cavity plates of thecavity assembly relative to each other along a cavity clamping axis,between a closed position in which the cavity plates abut in clampedcontact, and an open position in which the cavity plates are separatedfor removal of a molded article; a core clamping assembly comprising anactuator operable to move the mom core relative to me cavity assemblyalong a core clamp axis between a closed position in which the core isinterposed between the cavity plates to define the mold, and a removalposition in which the core is retracted for removal of a molded article.

In some embodiments, the core clamp axis is perpendicular to the cavityclamp axis.

In some embodiments, the actuator is operable to apply a force along thecore clamping axis to urge the mold core towards the cavity platesduring molding.

In some embodiments, the force is a preload force for resisting pressurefrom molding material in the mold.

In some embodiments, the actuator is operable to withdraw the mold corefrom a molded article along the core clamping axis.

In some embodiments, the core clamping assembly comprises a retainer forholding a molded article while the core is withdrawn.

In some embodiments, the actuator comprises a rotary crank and a linkassembly for causing a reciprocating motion.

In some embodiments, the crank assembly comprises an eccentric rotor.

In some embodiments, the apparatus is for injection molding.

In some embodiments, the apparatus comprises an injection orifice forreceiving a flow of molding material along the core axis.

In some embodiments, the core clamping axis is vertical.

In some embodiments, the injection orifice mates to a vessel forreceiving molding material from the vessel.

In some embodiments, the clamping assembly is operable to move both ofthe first and second cavity plates towards and away from one another.

An example apparatus for operating a mold having a cavity assembly and acore that cooperatively define a mold for molding of plastic articles,comprising: a carriage comprising a support plate;

a clamping assembly mounted to the support plate; first and second moldsupport plates mounted to the clamping assembly, and movable by theclamping assembly between a closed position in which cavity plates ofthe cavity assembly abut one another in clamped contact to define asurface of an article to be molded, and an open position for removal ofmolded articles; the clamping assembly operable to exert a clamp forceon the first and second mold support plates to hold the cavity plates inthe closed position during molding of an article, wherein the clampforce is applied through a central axis of the mold support plates.

In some embodiments, exerting the clamp force causes tensile loading ofthe support plate along a longitudinal axis thereof.

In some embodiments, the clamp force is applied along the longitudinalaxis of the support plate.

In some embodiments, the clamping assembly comprises a crank connectedto a linkage to move the clamping assembly through a reciprocatingstroke.

In some embodiments, the linkage comprises a link pivotably mounted tothe support plate.

In some embodiments, the clamping assembly is mounted to the supportplate such that exerting the clamp force creates substantially nobending moment in the support plate.

In some embodiments, the mold support plates are slidably supported bythe support plate.

In some embodiments, the support plate comprises guides for maintainingsquare orientation of the mold plates relative to one another.

In some embodiments, the clamping assembly is operable to move both ofthe first and second mold support plates towards and away from oneanother.

An example apparatus for injection molding comprises: a support base; amold carrier assembly removably mountable to the support base,comprising: a mounting plate having attachment features for engagingcorresponding attachment features on the support base; a mold comprisingfirst and second mold plates slidably supported on the mounting plate; aclamp mounted to the mounting plate, the clamp operable to move the moldbetween a closed state in which the mold plates abut one another, and anopen state in which the mold plates are spaced apart for removing moldedarticles.

In some embodiments, the mold carrier assembly comprises a motor coupledto the clamp.

In some embodiments, the mold carrier assembly comprises an adjustmentmechanism for moving the mold carrier assembly relative to the supportbase.

In some embodiments, the support base has an opening for removal of themold carrier assembly, and wherein the adjustment mechanism is operableto align the mold carrier assembly with the opening.

In some embodiments, the attachment features comprise locking pinsoperable to selectively engage corresponding guide blocks on the supportbase.

In some embodiments, the mold carrier assembly comprises couplings forengagement of the mold carrier assembly with a lifting tool.

In some embodiments, the couplings comprise hooks for lifting by acrane.

An example molding assembly for injection molding comprises: a moldcarrier assembly removably mountable to a support base, comprising: amounting plate having attachment features for engaging correspondingattachment features on the support base; a mold comprising first andsecond mold plates slidably supported on the mounting plate; a clampmounted to the mounting plate, the clamp operable to move the moldbetween a closed state in which the mold plates abut one another, and anopen state in which the mold plates are spaced apart for removing moldedarticles.

In some embodiments, the mold carrier assembly comprises a motor coupledto the clamp.

In some embodiments, the mold carrier assembly comprises an adjustmentmechanism for moving the mold carrier assembly relative to the supportbase.

In some embodiments, the adjustment mechanism is operable to align themold carrier assembly with an opening in the support base.

In some embodiments, the attachment features comprise locking pinsoperable to selectively engage corresponding guide blocks on the supportbase.

In some embodiments, the mold carrier assembly comprises couplings forengagement of the mold carrier assembly with a lifting tool.

In some embodiments, the couplings comprise hooks for lifting by acrane.

An apparatus for injection molding, comprising: a clamping assemblymounted to a support; a mold comprising first and second mold platesmounted to the clamping assembly, the mold movable by the clampingassembly between a closed position in which the cavity plates abut oneanother to define a surface of an article to be molded, and an openposition for removal of molded articles; the clamping assembly driven bya crankshaft and comprising a connecting link causing reciprocatingmotion of the mold during each rotation of the crankshaft.

In some embodiments, reciprocating motion of the first mold plate isdriven by a single connecting link coupled to the crankshaft.

In some embodiments, the single connecting link is coupled to the moldplate by a multi-bar linkage.

In some embodiments, the clamping assembly comprises first and secondconnecting links coupled to a common crankshaft, wherein the firstconnecting link drives reciprocating motion of the first mold plate andthe second connecting link drives reciprocating motion of the secondmold plate.

An example apparatus for operating a mold having a cavity and a corethat cooperatively define a mold for molding of plastic articlescomprises: a clamping assembly operable to move mold plates relative toeach other between a closed position in which the plates abut in clampedcontact, and an open position in which the plates are separated; a coreactuator operable to move the mold core relative to the plates along acore axis between a closed position in which the core is interposedbetween the plates, a preload position, in which the core is compressedfrom the closed position towards the plates, and a removal position inwhich the core is retracted for removal of a molded article.

In some embodiments, the apparatus comprises a spring load assembly forsupporting the mold against the plates, wherein movement of the corefrom the closed position to the preload position compresses the springload assembly.

In some embodiments, the mold core comprises an inner core and an outercore positioned around the outer core, wherein the actuator is operableto move one of the inner core and the outer core relative to the otherof the inner core and the outer core along the core axis.

In some embodiments, the actuator is operable to withdraw the inner corerelative to the outer core in the removal position, to dislodge a moldedpart from the inner core.

In some embodiments, the actuator is connected to the mold core withreleasable couplings.

In some embodiments, the actuator is mounted to a platen of the clampassembly.

In some embodiments, the apparatus comprises a slotted link connectingthe actuator to the mold core.

In some embodiments, the core axis is perpendicular to a clamping axisof the clamp assembly.

In some embodiments, the core clamping axis is vertical.

In some embodiments, the apparatus is for injection molding.

An example clamping apparatus for injection molding of plastic articles,comprising: a support frame; first and second platens suspended from thesupport frame, each the platen for mounting a respective mold plate; alinkage comprising a plurality of pivotably-connected members, thelinkage operable by pivoting the links around a vertical axis to movethe platens between a mold-closed position in which mold plates abut oneanother, and a mold-open position in which mold plates are spaced apartfrom one another.

In some embodiments, the apparatus comprises mounts for attaching thefirst and second platens to the support frame, wherein the mounts lie ina vertical plane.

In some embodiments, the mounts are attached to a vertical plate.

In some embodiments, the platens defines a mold bounding envelope inwhich mold plates are to mountable to the platens, the mold boundingenvelope comprising ends defined by the platens, top and bottom sides,and opposing lateral sides perpendicular to the platens, and wherein thesupport frame and the linkage are adjacent one of the lateral sides.

In some embodiments, a lateral side of the mold bounding envelopeopposite the support frame and the linkage is an access side throughwhich a material handling device may be inserted.

In some embodiments, the bottom side of the mold bounding envelope is anaccess side.

In some embodiments, in the mold-open position, mold plates can beremoved through a side of the mold bounding envelope.

In some embodiments, the platens are movable along a horizontal axis.

In some embodiments, the apparatus comprises a rotor driving thelinkage.

In some embodiments, the support frame is mounted to a tower structure.

Embodiments may include the above-described features in any suitablecombination.

Additional embodiments and features will be apparent to skilled personsin view of the disclosure herein.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings, which depict example embodiments:

FIG. 1 is a schematic diagram of a molding system;

FIG. 2 is a schematic diagram of a molding system with process cellsdefining multiple paths through the system;

FIG. 3 is an isometric view of a molding system;

FIG. 4A-4B are isometric views of a dispensing station of the system ofFIG. 3;

FIGS. 4C-4E are isometric views of sub-assemblies of the dispensingstation of FIG. 4A;

FIGS. 4F-4G are enlarged partial isometric views of a barrel unit;

FIG. 4H is a schematic view of a coupling for holding the barrel unit ofFIGS. 4F-4G to a drive unit;

FIGS. 4I-4J are enlarged partial isometric views of the barrel unit ofFIG. 4F with a drive unit;

FIG. 4K is a schematic diagram of a removal tool for removing a barrelunit from a drive unit;

FIGS. 4L-4O are enlarged partial cutaway views showing a process ofcoupling a barrel unit to a drive unit;

FIGS. 4P-4R are enlarged partial cutaway views showing a process ofremoving a barrel unit from a drive unit;

FIG. 4S is a schematic view of the removal tool of FIG. 4K installing abarrel unit to a drive unit;

FIG. 5 is a longitudinal cross-sectional diagram of the dispensingstation of FIG. 4;

FIGS. 6A-6B are isometric and isometric cutaway views, respectively, ofa vessel for transporting molding material;

FIGS. 7A-7B are isometric views of the material vessel of FIGS. 6A-6Band a carrier;

FIGS. 8A, 8B, 8C, and 8D are side and cross sectional views showingstages of a dispensing operation at the dispensing station of FIG. 4;

FIG. 9 is an exploded view of a gate assembly;

FIGS. 10A-10B are enlarged cross-sectional views showing operation ofthe gate assembly of FIG. 9;

FIG. 11 is an isometric view of a shaping station of the system of FIG.3;

FIGS. 12A-12D are cross-sectional and isometric views of the shapingstation of FIG. 11;

FIGS. 13A-13B are isometric and side views, respectively, of a linkagefor a clamping assembly; FIG. 13C is a diagram of forces on the linkageof FIGS. 13A-13B;

FIGS. 14A-14B are isometric and side views, respectively, of anotherlinkage for a clamping assembly;

FIGS. 15A-15B are isometric and side views, respectively, of anotherlinkage for a clamping assembly;

FIG. 16 is a side view of another linkage for a clamping assembly;

FIG. 17 is an isometric view of a core actuation assembly of the shapingstation of FIG. 11;

FIGS. 18A-18B are isometric and cross-sectional views, respectively, ofa core positioning actuator of the core actuation assembly of FIG. 17;

FIG. 19 is an isometric view of a loading actuator of the core actuationassembly of FIG. 17;

FIG. 20 is a partial cutaway view of the loading actuator of FIG. 19;

FIG. 21A is a schematic view showing interlocking between the corepositioning actuator of FIGS. 18A-18B and the loading actuator of FIG.17;

FIG. 21B is a partial cross-sectional view of the core positioningactuator of FIGS. 18A-18B and the loading actuator of FIG. 17, showinginterlocking;

FIG. 22 is an isometric view of a secondary mold opening actuator of thecore actuation assembly of FIG. 17;

FIGS. 23A-23D are side, isometric, enlarged top and enlarged perspectiveviews, respectively, of a shaper module of the shaping station of FIG.11;

FIG. 24A-24B are front isometric and top elevation views of anothersnapping station;

FIG. 24C is a rear isometric view of the shaping station of FIG. 24A;

FIG. 24D is front isometric view of support structures of the shapingstation of FIG. 24A;

FIGS. 24E-24F are isometric views of the support structures of FIG. 24D,cutaway at lines E-E and F-F in FIG. 24B;

FIG. 24G is an isometric view of the shaping station of FIG. 24A,cutaway to show internal components;

FIG. 24H is an enlarged partial cross-sectional of the shaping stationof FIG. 24A;

FIGS. 24I-24J are isometric and cross-sectional views of the shapingstation of FIG. 24A in a to mold-open state;

FIGS. 24K-24L are isometric and cross-sectional views of the shapingstation of FIG. 24A in a mold-open state, with the mold core in amolding position;

FIGS. 24M-24N are isometric and cross-sectional views of the shapingstation of FIG. 24A in a mold-closed state;

FIGS. 24O-24P are isometric and cross-sectional views of the shapingstation of FIG. 24A in a mold-closed state, with a preload force appliedto the mold core;

FIGS. 24Q-24R are isometric and cross-sectional views of the shapingstation of FIG. 24A in a mold-open state;

FIGS. 24S-24T are isometric and cross-sectional views of the shapingstation of FIG. 24A during mold removal;

FIG. 25A is a side perspective view of a one embodiment of part of amold assembly;

FIG. 25B is a front elevation view of a portion of the part of the moldassembly of FIG. 25A;

FIG. 25C are side perspective views of the embodiment of portions of thepart of the mold assembly of FIG. 25A;

FIGS. 25D, E and F are similar side perspective views as FIG. 25C, ofportions of the part of the mold assembly of FIG. 25A;

FIG. 25G is top perspective view of an embodiment of a mold cavityblock;

FIG. 25H is a is top perspective view of an embodiment of a cavity platethat includes the mold cavity block of FIG. 25G;

FIG. 25I is top perspective view of an alternate embodiment of a moldcavity block;

FIG. 25J is top plan view of the mold cavity block of FIG. 25I

FIG. 25K is another top perspective view of the mold cavity block ofFIG. 25I;

FIG. 26A and 26B are side perspective views of an alternate embodimentof portions of a mold assembly;

FIG. 26C is a top plan section view at part marked 26C in FIG. 26A;

to FIG. 26D is a side perspective view of part of the embodiment of theportions of the mold assembly of FIGS. 26A and 26B;

FIG. 26E is a perspective view of a disconnected components of the partshown in FIG. 26D;

FIG. 26F is a perspective view of another disconnected components of thepart shown in FIG. 26D;

FIG. 26G are rear elevation views of the disconnected component of thepart shown in FIG. 26D;

FIG. 26H is top plan view of the mold cavity block used in the part ofFIG. 26D;

FIG. 26I is a top perspective view of the mold cavity block of the partof FIG. 26D;

FIG. 26J is a top perspective view of an alternate mold cavity blockthat can be employed in the part of FIG. 26D;

FIG. 27A is a top perspective view of a base block;

FIG. 27B is a rear perspective view of the base block of FIG. 27A;

FIG. 28A is an assembly diagram for part of a mold assembly; and

FIG. 28B is a schematic view of a cooling fluid circuit.

FIG. 29 is a cross-sectional view of a mold of the shaping station ofFIG. 11 and a vessel;

FIG. 30 is a sequence of overhead and isometric views showing sealing ofa vessel;

FIG. 31 is an isometric view showing sealing of another vessel;

FIG. 32 is an isometric view of the actuator assembly of the shapingstation of FIG. 11;

FIGS. 33A, 33B and 33C are isometric, cutaway and cross-sectional views,respectively, of a vessel and an actuation assembly at the shapingstation of FIG. 11;

FIGS. 34A-34K are cross-sectional and partial cross-sectional viewsshowing stages of a shaping operation at the shaping station of FIG. 11;

FIGS. 35A-35F are cutaway views of the vessel and actuation assembly ofFIGS. 17A-17C, showing operations of the vessel and actuation assembly;

FIG. 36 is an exploded view of a gate assembly;

FIGS. 37A-37B are enlarged cross-sectional views showing operation ofthe gate assembly of FIG. 36;

FIG. 38 is an isometric view of a conditioning station and a shapingstation of the system of FIG. 3.

FIG. 39 is a side cross-sectional view of the conditioning station ofFIG. 38;

FIGS. 40A, 40B and 40C are side and cross-sectional views showing stagesof a conditioning operation at the conditioning station of FIG. 38;

FIG. 41A is an isometric view of a shaping station;

FIG. 41B is a side view of a press of the shaping station of FIG. 41;

FIG. 42 is a side view of another shaping station;

FIG. 43 is a top view of the shaping station of FIG. 42;

FIG. 44 is an exploded view of a mold and services plates of the shapingstation of FIG. 42;

FIG. 45 is an exploded view of the mold of FIG. 44;

FIG. 46 is a cross-sectional view of the mold of FIG. 44;

FIGS. 47A-47B are top and side schematic views of the shaping station ofFIG. 42 during mold removal;

FIGS. 48A-48B are top and side schematic views of the shaping station ofFIG. 42 during mold removal;

FIGS. 49A-49B are top and side schematic views of the shaping station ofFIG. 42 during mold removal;

FIG. 50 is a schematic view showing mold components at a shapingstation;

FIGS. 51A, 51B, 51C and 51D are schematic views showing stages of ashaping operation with the mold components of FIG. 50;

FIG. 52 is a top plan view of the molding system of FIG. 3, showing atransport subsystem;

FIG. 53 is a plan view of an injection molding system in accordance withanother embodiment;

FIG. 54 is a cross-sectional view along the lines I-I of FIG. 53;

FIG. 55A is a side view of a track section;

FIG. 55B is a cross-sectional view along the lines II-II of FIG. 55A;

FIG. 55C is a perspective fragmentary view of a portion of the track ofthe system of FIG. 55A;

FIG. 56 is a side view of a portion of the system of FIG. 53;

FIG. 57 is a perspective fragmentary view of another portion of thesystem of FIG. 53;

FIG. 58 is a perspective fragmentary view of a further portion of thesystem of FIG. 53;

FIG. 59 is a perspective fragmentary view of a yet a further portion ofthe system of FIG. 53;

FIG. 60 is a perspective detail view of a portion of FIG. 58;

FIG. 61 is a top view of a conditioner and shaper station and associatedtransfer system;

FIG. 62 is a side view of the stations and transfer system of FIG. 61

FIGS. 63A-63B are isometric and side views, respectively, of a carriageof the transfer system or FIG. 61;

FIG. 64 is a block diagram;

FIG. 65 is a perspective fragmentary view of a portion of a modifiedsystem;

FIG. 66 is a perspective detail view of a portion of FIG. 63.

FIG. 67 is a flow chart showing a method of transporting moldingmaterial; and

FIG. 68 is a flow chart showing a method of producing plastic moldedproducts.

DETAILED DESCRIPTION

FIG. 1 schematically depicts an example plastic molding system 100 forproducing plastic molded articles. As described in further detail below,plastic molding system 100 is capable of carrying out molding processescomprising dispensing, conditioning and shaping operations.

Plastic molding system 100 includes a plurality of process cells, eachincluding one or more process stations at which an operation of amolding process can be performed. Specifically, the depicted embodimentcomprises a dispensing cell 102, shaping cells 104, 106 and aconditioning cell 108. Other embodiments may include more or fewer cellsand carry out molding processes with more or fewer process steps.Alternatively or additionally, plastic molding system 100 may includecells for other operations. For example, plastic molding system 100 mayinclude cells for post-molding operations such as container filling,labelling or capping.

The process cells of plastic molding system 100 are connected by atransport subsystem 110.

Any of process cells 102, 104, 106, 108 may have more than one stationof a given type. Transport subsystem 110 selectively connects stationsof the process cells to one another. Transport subsystem 110 isconfigurable to define multiple possible process paths through processcells of molding system 100. For example, transport subsystem 110 may becapable of transporting an article from a given station in one processcell 102, 104, 106, 108, to a selected one of a plurality of possiblestations in another process cell 102, 104, 106, 108.

FIG. 2 schematically depicts an example embodiment with a dispensingcell 102 having 4 dispensing stations 102-1, 102-2, 102-3, 102-4; ashaping cell 104 having 8 shaping stations 104-1, 104-2, 104-3, 104-4,104-5, 104-6, 104-7, 104-8; a shaping cell 106 having 2 shaping stations106-1, 106-2; and a conditioning cell 108 having 2 conditioning stations108-1, 108-2.

In the embodiment of FIG. 2, transport subsystem 110 is capable ofconnecting any of dispensing stations 102-1, 102-2, 102-3, 102-4 to anyof shaping stations 104-1, 104-2, . . . 104-8; and of connecting any ofshaping stations 104-1, 104-2, . . . 104-8 to any of conditioningstations 108-1, 108-2; and of connecting any of conditioning stations108-1, 108-2 to any of shaping stations 106-1, 106-2. Thus, numerouspossible paths are defined through molding system 100. As depicted,there exist 128 unique combinations of one dispensing station 102, oneshaping station 104, one conditioning station 108 and one shapingstation 106 and each unique combination corresponds to a possible path.In some embodiments, one or more of the process cells may be omittedfrom some paths, such that additional paths are possible. For example,conditioning at conditioning cell 108 or shaping at shaping cell 106 maynot be required in all instances.

In other embodiments, more or fewer stations may be present in eachprocess cell, and more or fewer paths through the molding system may bepossible.

In some embodiments, process cells or stations of process cells may bephysically separated from one another. Transport subsystem 110 mayinclude apparatus for moving molding material through space betweenprocess cells or stations thereof. The apparatus may include one or bothof vessels 124 (FIGS. 6A-6B) for holding molding material and carriers125 (FIG. 7) for moving the vessels through space, e.g. along a guide ortrack, between the process cells or stations. In the embodimentdescribed in detail herein, the vessel is selectively coupled to thecarrier such that the vessel may be coupled and decoupled to the carrierat one or more process stations. In another embodiment, not shown, thevessel could otherwise be fixed to the carrier and the process stationsconfigured to accommodate the vessel that remains connected with thecarrier. In either case, the vessel may be thermally insulated from thecarrier.

In the depicted embodiment, shaping cell 104 contains injection moldingstations and shaping cell 106 contains blow molding stations.Conditioning cell 108 contains stations for thermally conditioningarticles to prepare for blow molding. For example, injection moldedarticles formed at shaping cell 104 may cool after molding and besubsequently warmed to a temperature suitable for blow molding.Alternatively or additionally, stations of conditioning cell 108 may beconfigured to create a specific desired thermal profile in an article.For example, some shaping operations may call for an input articlehaving a non-uniform temperature distribution. Stations of conditioningcell 108 may generate such temperature distribution by selectivelyheating specific regions, with or without a net transfer of heat into orout of the article. In some embodiments, articles may experience a netloss of heat in conditioning cell 108, despite warming of specificregions. Thus, stations of conditioning cell 108 may achieve thermalprofiles not easily achieved by heat input at the dispensing cell 102.

As explained in further detail below, each station may have identical orunique characteristics. For example, the dispensing stations ofdispensing cell 102 may each be configured to dispense the same or adifferent feedstock (e.g. a different material and/or colour). Theshaping stations of shaping cells 104, 106 may be configured to moldarticles having identical or different shapes, features or the like. Theconditioning stations of conditioning cell 108 may each be configured tocondition parts in common or to a different state. Accordingly, moldingsystem 100 may be configured so that it is simultaneously capable ofproducing up to 128 identical or unique parts at any time. Alternativelyor additionally, molding system 100 may be configured so that identicalparts may be produced on multiple paths. For example, a singledispensing station can produce shots of feedstock to feed multiplestations of shaping cells 104, 106. In some embodiments, cells can berapidly reconfigured. Accordingly, the number of system resources beingused to produce parts of a given type may vary.

Each unique path through molding system 100 includes a uniquecombination of selected stations of dispensing cell 102, shaping cells104, 106 and possibly other process cells such as, for example, theconditioning cell 108. Likewise, each unique combination of stations mayproduce finished articles with identical or unique characteristics. Forexample, different stations of dispensing cell 102 may produce articleshaving different colour material type or weight. Different stations ofshaping cells 104, 106 may produce articles having different shapes.Different stations of conditioning cell 108 may produce articles havingdifferent shapes or other characteristics.

FIG. 3 is a perspective view of molding system 100. In the depictedembodiment, molding system 100 is for forming hollow plastic articlessuch as bottles or other containers. Molding system 100 has two shapingcells. Specifically, shaping cell 104 is an injection molding cell formolding a dose of feedstock material into a molded preform shape.Shaping cell 106 is a blow-molding cell (specifically, a stretchblow-molding cell) for transforming a preform of a particular shape intoa finished hollow container of another, (e.g. a further-expanded) shape.Conditioning cell 108 prepare in-progress articles for operationsperformed at a shaping cell. Transport subsystem 110 links stations ofthe respective cells 102, 104, 106, 108. Links between cells areflexible. For example, in some embodiments, transport subsystem 110links every station of each cell to every station of the neighboringcells. In other examples, some or all stations in a given cell are eachlinked to a plurality of stations in a neighboring cell. In someexamples, some stations may be linked to stations of neighboring cellsin a 1:1 manner. For instance, in the embodiment of FIG. 3, each stationof dispensing cell 102 is linked to a plurality of stations of shapingcell 104, and each station of shaping cell 104 is linked to a pluralityof stations of conditioning cell 108. However, each station ofconditioning cell 108 is linked to one corresponding station of shapingcell 106.

Feedstock Dispensing

With primary reference to FIGS. 4A-4S, details of an example dispensingcell 102 will now be described.

Each station 102-1, 102-2, 102-3, 102-4 of dispensing cell 102 comprisesone or more devices for melting a feedstock such as a plastic feedstockand for transferring the feedstock. In the depicted embodiment, thedispensing devices output molding material in doses or a specific size.However, in other embodiments, the dispensing devices may simply performbulk transfer of molding material, without precise metering of dosesize.

In the depicted embodiment, each station of dispensing cell 102comprises an extruder 112. However, other types of dispensing devicesare possible. For example, melting and dispensing doses of feedstock maybe accomplished by use of a conduction melter. In the depicted example,extruders 112 receive feedstock material in the form of polyethyleneterephthalate (PET) pellets. However, other feedstock materials andother forms are possible. For example, feedstock may be provided as afilament (e.g. on a spool), or as bars or blocks.

Extruders 112 may dispense different feedstock materials. In someexamples, extruders 112 may dispense feedstock materials in differingvolume, colors, different material types or grades, or at differenttemperatures. In some embodiments, extruders may be capable of dosing orblending additives, such as dyes or oxygen scavenging agents, into thefeedstock material. In some embodiments, extruders 112 may be ofdifferent sizes, or may be configured to dispense feedstock at differentrates or in different dose sizes. For example, system 100 may be set upto form containers of different size, with each extruder 112 beingconfigured to dispense feedstock in doses corresponding to a specificsize.

FIGS. 4A-4B are isometric and exploded views, respectively of anextruder 112 showing components thereof in greater detail. As depicted,extruder 112 has a barrel 114, in which a screw 116 (FIG. 5) is housed,and a drive unit 115 for driving rotation of the screw 116. Rotation ofthe screw 116 is driven by a drivetrain 130 within drive unit 115, whichmay include an electric motor. Barrel 114 has an inlet opening forsupply of feedstock and an outlet orifice 122 (FIG. 5) for dispensing ofmolten feedstock into a vessel 124.

Referring to FIG. 4B, in the depicted embodiment, extruders 112 aremounted to supports 162 within dispensing cell 102. A set of supports162 may be provided for each dispensing station 102-1, 102-2, 102-3,102-4. As depicted, barrel 114 and the screw 116 within barrel 114(collectively referred to as barrel unit 117) are releasably coupled todrive unit 115. Specifically, a coupling 161 rotationally couples thescrew 116 to drivetrain 130 and one or more locating features 163 arereceived in corresponding recesses of supports 162 to position andsecure barrel 114 relative to the support 162. Alternatively, alignmentfeatures 163 may be part of supports 162 and may be received incorresponding recesses on barrel 114. Supports 162 may include actuatorsfor selectively engaging or releasing locating features 163. Thus,barrel 114 and screw 116 may be released and removed as a unit andreplaced by another barrel 114 and screw 116. Coupling 161 and locatingfeatures 163 are located on one or both of a coupling block 4010 ofbarrel unit 117 and a frame 4012 of drive unit 115. References herein toremoval, replacement or installation of extruders 112 are intended toinclude removal, replacement or installation of a barrel 114 and screw116 as an assembly. In this way, extruder characteristics orcharacteristics of a feedstock may be rapidly and easily changed.

In some embodiments, removal, replacement or installation of extruders112 may be affected automatically. For example, extruders 112 may begripped and removed from supports 162 and may be moved by one or morerobots under computer control. The computer control may be part of anoverall control system of system 100, and releasing or engaging oflocating features such as locating features 163 on barrel 114 may becoordinated with operation of the robot, such that extruders 112 aresecurely retained upon installation by a robot, and until subsequentremoval by a robot.

FIGS. 4C and 4D depict barrel unit 117 and drive unit 115 of an extruder112 in greater detail. In the configuration of FIG. 4C, barrel unit 117is coupled to drive unit 115. In the configuration of FIG. 4D, barrelunit 117 is released from drive unit 115.

As depicted, barrel unit 117 includes a barrel 4002 and a screw 116within barrel 4002. A nozzle assembly 4006 is positioned at the distalend of barrel 4002, in which outlet orifice 122 is defined. Rotation ofscrew 116 within barrel 4002 causes heating and melting of moldingmaterial, and conveys the molding material towards outlet orifice 122 innozzle assembly 4006. A shroud 4008 is positioned around barrel 4002.During operation, barrel 4002 may become very hot. Shroud 4008 serves asa barrier to guard against damage to surrounding components and toprotect against injury to operators.

Barrel 4002 is mounted to coupling block 4010. For example, barrel 4002may have a flange (not shown) which interfaces with block 4010 and issecured thereto by fasteners. As will be described in greater detail,screw 116 is received in and supported by barrel 4002.

Nozzle assembly 4006 includes a thermal conditioning element 4007proximate outlet 122. Thermal conditioning element 4007 maintains nozzleassembly 4006 at a desired temperature, to in turn control thetemperature of molding material in nozzle assembly 4006 and moldingmaterial exiting nozzle assembly 4006 through outlet 122. One or moretemperature measurement devices such as thermocouples may be positionedat nozzle assembly 4006, and thermal conditioning element 4007 may becontrolled based on measurements from such devices.

Drive unit 115 and barrel unit 117 are connected by way of a couplingsystem operated by one or more actuators. The one or more actuators areoperable to couple and decouple the drive unit 115 and barrel unit 117using the coupling system. That is, the coupling system is operable tophysically fix barrel unit 117 in position relative to drive unit 115.The coupling system is further operable to connect screw 116 with thedrive unit 115 for driving rotation of the screw 116. In the depictedembodiment, the coupling system includes a retaining mechanism 4014 anda drive mechanism 4016. Retaining mechanism 4014 is operable tophysically hold barrel unit 117 in place against drive unit 115. Drivemechanism 4016 rotationally connects drive unit 115 to screw 116 forrotating the screw.

In the depicted embodiment, retaining mechanism 4014 and drive mechanism4016 are operated by separate actuators. In other embodiments, a singleactuator may operate both of retaining mechanism 4014 and drivemechanism 4016. In other embodiments, a single mechanism may provideboth the retention and drive functions.

In the depicted embodiment, the actuators for retaining mechanism anddrive mechanism 4016 are pneumatic. However, other types of actuatorsmay be used, including electro-mechanical actuators such as solenoids,magnetic actuators, or hydraulic actuators.

Barrel unit 117 further includes one or more service ports 4018, eachfor connecting to a corresponding port of drive unit 115 or proximatedrive unit 115. Service ports may include, for example, conduits forcirculation of coolant such as water to and from barrel unit 117,conduits for supply of air, e.g. pressurized air for pneumatic actuationsystems, and electrical connections. Electrical connections may,include, for example, any of power supplies, controls, and signalwiring. Drive unit 115 also includes a resin feed port 4076 (FIG. 41).Resin feed port 4076 receives a feed of molding material, e.g.pelletized molding material, and communicates with barrel unit 117 tosupply molding material to the barrel. Service ports 4018 may beconfigured for quick connection to and disconnection from thecorresponding ports of drive unit 115. In an example, service ports 4018may couple using push-to-connect pneumatic or hydraulic connectors,magnetic connectors, barb fittings or the like. Thus, service ports 4018may automatically connect or disconnect from the corresponding ports byapplication of force, e.g. due to movement of barrel unit 117, or inresponse to a control signal.

FIG. 4E depicts barrel unit 117, with coupling block 4010 and shroud4008 removed to show internal features. Barrel unit 117 has a resininput port 4074 which communicates with the interior of barrel 4002 todeliver molding material to the interior of barrel 4002. Moldingmaterial is typically input to barrel 4002 in solid granular form andmay be delivered, e.g. from a hopper (not shown). The hopper may bemounted to drive unit 115 or proximate drive unit 115 and delivermolding material to resin input port 4074 by way of a correspondingresin feed port 4076 on drive unit 115. In some embodiments, resin inputport 4074 and resin feed port 4076 abut one another. In otherembodiments, one of input port 4074 and feed port 4076 may be receivedwithin the other. In some embodiments, input port 4074 and feed port4076 may be positively coupled to one another, for example, using quickconnect fittings such as push-to-connect pneumatic or hydraulicconnectors, magnetic connectors, barb fittings or the like. Connectionand disconnection of such fittings may be automatically affected byapplication of force, e.g. due to movement of barrel unit 117, or inresponse to a control signal.

As best shown in FIG. 4F-4G, one or more locating devices may beprovided to position drive unit 115 and barrel unit 117. The locatingdevices position barrel unit relative to drive unit 115 as the barrelunit is moved toward a coupling position. Specifically, the locatingdevices guide barrel unit 117 so that it seats against drive unit 115 ina coupling position, in which retention mechanism 4014 and drivemechanism 4016 can be engaged. That is, in the coupling position,components of the retaining mechanism 4014 and drive mechanism 4016 onbarrel unit 117 align with the corresponding components on drive unit115. The locating devices may progressively bias barrel unit 117 intoits correct alignment as the barrel unit 117 is moved towards drive unit115. In the depicted embodiment, the locating devices comprise leaderpins 4020 and mating recesses 4022 (FIG. 4D). As shown, leader pins 4020project from coupling block 4010 of barrel unit 117 and are received inrecesses 4022 in frame member 4012 of drive unit 115.

Leader pins 4020 and recesses 4022 engage one another as barrel unit 117is moved toward drive unit 115. Such engagement aligns barrel unit 117relative to drive unit 115 such that the barrel unit 117 and drive unit115 can be coupled by actuation of retaining mechanism 4014. In thedepicted example, the alignment devices engage one another prior toengagement of the coupling system.

FIG. 4H depicts retaining mechanism 4014 in greater detail. In thedepicted embodiment, retaining mechanism 4014 includes a stud 4024 and asocket 4026 which can selectively interlock with stud 4024. As shown,stud 4024 is part of barrel unit 117 and socket 4026 is part of driveunit 115. Stud 4024 may, for example, be threaded to coupling block4010. Socket 4026 may be a recess cut into frame 4012 or an insertattached (e.g. threaded) to frame 4012. However, socket 4026 may insteadbe part of barrel unit 117 and stud 4024 may instead be part of driveunit 115.

Stud 4024 has inner and outer flanges 4028, defining a channel 4032therebetween. Socket 4026 has an opening 4034, sized to receive stud4024, and a gripping device 4036. Gripping device 4036 is configured forreception in channel 4032, in interlocking engagement with flanges 4028.

Gripping device 4036 is movable between engaged and disengaged states.In the disengaged state, gripping device 4036 clears flanges 4028 ofstud 4024 such that stud 4024 may be freely inserted in or withdrawnfrom socket 4026. In the engaged state, gripping device interlocks withstud 4024, preventing stud 4024 from being withdrawn from socket 4026.

In the depicted embodiment, gripping device 4036 comprises a series ofballs 4038 and a movable locking collar 4040. In the engaged state,locking collar 4040 holds balls 4038 against channel 4032. Balls 4038bear against the distal flange 4028 of stud 4024, urging stud 4024 (andbarrel unit 117) against drive unit 115. In the disengaged state,locking collar 4040 is withdrawn, allowing balls 4038 to shift away fromstud 4024.

As shown, locking collar 4040 is spring-biased to the engaged state. Anactuator is provided to selectively overcome the spring bias and therebyrelease locking collar 4040 and balls 4038. In the depicted embodiment,the spring bias is overcome by pneumatic pressure provided by aretention control line 4044, which is controlled by a valve (not shown).

Drive mechanism 4016 is shown in detail in FIGS. 4I-4J. Drive mechanism4016 includes a driveshaft 4050 driven by an electric motor (not shown).Driveshaft 4050 has an end with a toothed connector, e.g. spline 4052.The connector interfaces with a mating connector of screw 116, namely,spline 4054. As shown, spline 4052 of drive unit 115 and spline 4054 ofscrew 116 interface by way of a spline insert 4056.

Spline insert 4056 mates to both of splines 4052, 4054. Spline insert4056 is movable along the axis of rotation of driveshaft 4050, betweenan engaged position and a retracted position.

In the engaged position, spline insert 4056 meshes with splines 4052,4054 and rotationally couples driveshaft 4050 and screw 116. In theretracted position, spline insert 4056 is retracted along the axis ofdriveshaft 4050, to disengage from spline 4054 of screw 116. Thus, inthe retracted position of spline insert 4056, driveshaft 4050 and screw116 are de-coupled from one another. Retraction of spline insert 4056may occur without any movement of driveshaft 4050. That is, splineinsert may move along a longitudinal axis relative to both of driveshaft4050 and spline 4054 of screw 116 to disengage.

The position of spline insert 4056 is controlled by an actuator, namely,drive actuation assembly 4060. As shown, drive actuation assembly 4060includes a pneumatic cylinder 4062. The piston of pneumatic cylinder4062 is connected to spline insert 4056 by way of a link 4064. Movementof the piston through its stroke in a first direction moves splineinsert 4056 to its engaged position. Movement of the piston through itsstroke in the opposite direction moves spline insert 4056 to itsdisengaged position.

A shroud is also coupled to link 4064 and moves along with link 4064 andspline insert 4056. In the engaged position, the shroud is positionedaround the mating interface between spline insert 4056 and spline 4054of screw 116. The shroud guards against ingress of objects or tocontaminants such as dust or other particulates, which may causepremature wear or reduced performance of the splines 4052, 4054.

Splines 4052, 4054 and spline insert 4056 define mating interfaces,namely interfaces between mating teeth at which torque can betransferred. The mating faces have relatively large axial length, suchthat the mating interfaces can accomodate some movement of driveshaft4050 and screw 116 along their longitudinal axes. In other words, screw116 and driveshaft 4050 can shift axially relative to one anotherwithout interfering with meshing of splines 4052, 4054 and spline insert4056.

Screw 116 is rotationally supported by a bearing 4070 which is in turnsupported on coupling block 4010 by a flange 4071. A support ring 4072is secured to screw 116 above bearing 4070, by press-fit or othersuitable technique.

In operation, screw 116 may be vertically supported at least in part byfriction between spline insert 4056 and spline 4054 and by pressure ofmolding material within barrel 114. In this condition, there may beclearance between support ring 4072 and bearing 4070. When operation isterminated, screw 116 may fall until support ring 4072 abuts bearing4070. Support ring 4072 is positioned such that, when screw 116 falls inthis manner, a clearance gap opens between the ends of screw 116 anddrive shaft 4050. In this state, drive unit 117 may be moved withoutrubbing and consequent wearing of drive shaft 4050 and screw 116 againstone another.

Conveniently, in the depicted embodiment, engagement and disengagementof drive mechanism 4016 and retaining mechanism 4014 may occurindependently of one another. That is, drive mechanism 4016 may beengaged or disengaged without changing the state of retaining mechanism4014. Engagement of drive mechanism 4016 occurs by movement along thelongitudinal axis of screw 116, and barrel unit 117 is physicallylocated relative to drive unit 115 by movement in a perpendiculardirection. Likewise, physical fixation of barrel unit 117 to drive unit115 occurs by clamping in a direction perpendicular to the axis of screw116, i.e. in a direction perpendicular to that in which engagement ofdrive mechanism 4016 occurs. Alignment of barrel unit 117 relative todrive unit 115 also occurs by movement along an axis perpendicular tothat of screw 116. That is, leader pins 4020 extend in a directionperpendicular to the axis of screw 116. Independent operation of drivemechanism 4016 and retaining mechanism 4014 could also be achieved inother configurations. For example, the mechanisms could be configured toengage by movement along parallel axes, but the movements could beindependent of one another.

Coupling block 4010 comprises at least one mating surface 4076. Whenbarrel unit 117 is coupled to drive unit 115, mating surface 4076 abutsa corresponding face of drive unit 115 (i.e. a corresponding face offrame 4012). Mating surface 4076 may bear against frame 4012 to holdbarrel unit 117 square to drive unit 115.

In some embodiments, mating surface 4076 may be located so as to limitstress on drive mechanism 4016. For example, as shown in FIG. 4F, matingsurface 4076 is located at a central plane C of coupling block 4010.Longitudinal axis L of screw 116 lies within central plane C.

In operation, forces may be exerted on the tip of barrel 114. Suchforces may include axial forces, i.e. forces parallel to longitudinalaxis L, and transverse forces perpendicular to longitudinal axis L.Transverse forces may for example be caused by misalignment. The lengthof barrel 114 may act as a moment arm, such that transverse forces exerttorque on barrel 114.

Contact between mating surface 4076 and frame 4012 may resist torque onbarrel 114. That is, frame 4012 may exert reaction forces on matingsurface 4076 which resist movement or twisting of barrel unit 117.

Alignment of plane C and longitudinal axis L may limit stress on barrel114 and on spline 4054. Conversely, if place C and longitudinal axis Lwere spaced apart, transverse forces could also act around a secondarymoment arm, perpendicular to longitudinal axis L. Alignment of matingface 4076 and longitudinal axis L avoids such secondary moment arms andtherefore limits the torque to which spline 4054 and barrel 114 may besubjected.

Coupling block 4010 has a rear surface 4078 opposite mating surface4076. When barrel unit 117 is coupled to drive unit 115, rear surface4078 faces outwardly, away from drive unit 115. At least one pull stud4080 is fixedly attached (e.g. threaded) to coupling block 4010. Eachpull stud 4080 protrudes from coupling block 4010 for engagement by aremoval tool to remove barrel unit 117 from drive unit 115.

FIG. 4K shows an example removal tool 4082. Removal tool 4082 is anautomated (e.g. robotic) transportation device. Removal tool 4082 has abase 4084 and a rack 4086 supported on the base. Rack 4086 has aplurality of nests 4088, each capable of engaging and retaining a barrelunit 117. Two nests 4088-1 and 4088-2 are shown in FIG. 4K. However, anynumber of nests may be present.

Each nest 4088 has one or more couplings 4090 operable to selectivelyengage pull studs 4080. In some embodiments, couplings 4090 may beidentical to gripping devices 4036 of drive unit 115 and pull studs 4080may be identical to studs 4024 of barrel unit 117. Couplings 4090 arecontrolled by actuators (not shown). The actuators may be, for example,electronic, pneumatic or hydraulic actuators.

Rack 4086 may be mounted to base 4084 with a movable arm 4092. Arm 4092is operable to extend to engage a barrel unit 117 for removal from driveunit 115, and to retract for transportation once the barrel unit issecured in a nest 4088. Arm 4092 may, for example, be drive by anelectric servomotor or by a hydraulic or pneumatic cylinder.

As noted, plastic molding system 100 may include a plurality of barrelunits 117, which may be interchangeably mountable to one or more driveunits 115. For example, each barrel unit 117 may contain a differenttype of molding material, such as a different resin type differentcolour of material or the like.

Interchangeability of barrel units 117 may allow for rapid setup ofmolding system 100 to produce a specific variety of molded part. Removaltool 4082 may allow for automated changing of barrel units 117 at adrive unit 115. That is, removal tool 4082 may be capable ofautomatically approaching a drive unit 115, engaging a barrel unit 117installed at that drive unit 115, removing the barrel unit 117 andretaining it, and installing a new barrel unit 117. Removal tool 4082may then be capable of automatically transporting the removed barrelunit to a storage or cleaning area.

FIGS. 4L-4O depict a process of installing a barrel unit 117 to a driveunit 115.

As shown in FIG. 4L, a barrel unit 117 is carried by removal tool 4082to a position facing drive unit 115. In some embodiments, removal tool4082 may be guided into position relative to drive unit 115. Forexample, a beacon, such as an infra-red or other light-based beacon, ora radio-frequency (RF) beacon may be installed at drive unit 115 orbarrel unit 117 and corresponding sensors may be installed at removaltool 4082. Removal tool 4082 may be programmed to detect signals fromthe beacon and move toward the detected signals. In other embodiments,removal tool 4082 may be programmed to monitor and record its position.For example, removal tool 4082 may initially be manually moved intoposition at a particular drive unit 115 and may record coordinatescorresponding to that position. Thereafter, on receipt of a specificinstruction, removal tool 4082 may automatically return to the recordedposition. In some embodiments, removal tool 4082 may be programmed inthis manner to retain a number of transfer positions, each for engagingwith a respective drive unit 115.

With removal tool 4082 aligned with drive unit 115, arm 4092 is extendedto move the barrel unit 117 towards drive unit 115.

As barrel unit 117 approaches drive unit 115, gripping devices 4036 ofbarrel unit 117 are opened. In the depicted embodiment, opening ofgripping devices 4036 entails energizing the gripping device to overcomea spring bias towards the closed state. Energizing may be by providing astream of pressurized air or water, or by an electrical signal.

Alignment devices on the barrel unit 117 and drive unit 115 engage oneanother to position barrel unit 117 relative to drive unit 115.Specifically, leader pins 4020 are received in recess 4022 and guidebarrel unit 117 onto drive unit 115.

As shown in FIG. 4M, stud 4024 is received in socket 4026. The taperedleading end of stud 4024 may bear against walls of socket 4026 oragainst gripping device 4036 to provide fine alignment of stud 4024.

What barrel unit 117 is being installed, screw 116 is supported bysupport ring 4072 resting atop bearing 4070. In this condition, withbarrel unit 117 positioned so that stud 4024 aligns with socket 4026 ofdrive unit 115, a clearance gap exists between the ends of screw 116 anddrive shaft 4050. Thus, as barrel unit 117 is moved into position, screw116 passes below drive shaft 4050 and spline insert 4056 withoutcontacting either the drive shaft or the spline insert.

As shown in FIG. 4N, Barrel unit 117 is moved towards drive unit 115until stud 4024 is fully received within socket 4026. The retainingactuator is activated to close gripping device 4036, thereby lockingstud 4024 and barrel unit 117 in place relative to the drive unit 115.Engagement of stud 4024 by gripping device 4036 pulls stud 4024 andbarrel unit 117 towards drive unit 115. With stud 4024 so engaged,mating surface 4076 of coupling block 4010 is clamped tightly againstdrive unit 115. In some embodiments, gripping device 4036 remainsclosed, engaging stud 4024 unless energy is applied to release it, forexample, in the form of hydraulic or pneumatic pressure.

As shown in FIG. 40, with barrel unit 117 physically fixed to drive unit115, drive mechanism 4016 may be activated to rotationally couple screw116 to a motor by way of drive shaft 4050. A signal is provided to driveactuation assembly 4060, causing pneumatic cylinder 4062 to extend andmove spline insert 4056 to its engaged position. Extension of splineinsert 4056 causes spline insert 4056 to mesh with spline 4054, therebyrotationally coupling screw 116 to drive shaft 4050 and the motordriving drive shaft 4050.

FIGS. 4P-4R and 4S depict a process of removing a barrel unit 117 from adrive unit 115.

As shown in FIG. 4P, drive actuation assembly 4060 disengages drivemechanism 4016 prior to movement of barrel unit 117. Drive actuationassembly 4060 receives a signal causing retraction of cylinder 4062 andthus, of spline insert 4056. Retraction of spline insert 4056 releasesthe mesh between spline insert 4056 and spline 4054 so that screw 116and drive shaft 4050 can rotate independently of one another.

Screw 116 may fall so that support ring 4072 supports drive screw 116 onbearing 4070. Screw 116 may fall immediately after retraction of splineinsert 4056, or after pressure of molding material within barrel 114 isreduced. When supported by support ring 4072 on bearing 4070, and withspline insert 4056 retracted, screw 116 does not contact drive shaft4050 or spline insert 4056 and barrel unit 117 is clear of drive shaft4050 and spline insert 4056 for removal.

As shown in FIG. 4S, removal tool 4082 approaches barrel unit 117 andarm 4092 extends into contact or nearly into contact with barrel unit117.

Gripping devices 4036 of drive unit 115 are energized so that theyrelease stud 4024. Couplings 4090 of removal tool 4082 are positioned onpull stud 4080 of barrel unit 117 and are locked in a closed positionengaging the pull studs. Locking of couplings 4090 holds the barrel unit117 to nest 4088 and to rack 4086 of removal tool 4082.

With barrel unit 117 locked to arm 4092, removal tool 4082 retracts thearm to pull barrel unit 117 away from drive unit 115. Stud 4024 iswithdrawn from socket 4026 and service ports 4018 and resin input port4076 decouple from the corresponding ports of drive unit 115. Thealignment mechanism also decouples, as leader pins 4020 are withdrawnfrom recesses 4022 (not shown).

After barrel unit 117 is removed from drive unit 115, a new barrel unitmay be installed. In some examples, removal tool 4082 moves the newbarrel unit into alignment with drive unit 115. Specifically, removaltool 4082 may shift a nest 4088 carrying the new barrel unit intoalignment with drive unit 115.

With the new barrel unit aligned, removal tool 4082 extends arm 4092 tocouple the new barrel unit to drive unit 115, as described above withreference to FIGS. 4L-4O.

In some examples, the removed barrel unit 117 may remain in its nest4088 on arm 4092 while a new drive unit at another nest 4088 isinstalled to drive unit 115. Removal tool may arrive at drive unit 115carrying a first barrel unit, and may automatically remove a secondbarrel unit from the drive unit 115 and replace the second barrel unitwith the first barrel unit.

Upon removal from drive unit 115, a barrel unit may be stored. Thebarrel unit may, for example, be transferred from the removal tool 4082to a rack or other storage area. Alternatively, the barrel unit maysimply remain on the removal tool 4082 for storage. In some examples, aplurality of removal tools 4082 may be present, and each stored barrelunit may be stored on a removal tool having at least one vacant nest4088. Accordingly, any stored barrel unit could be installed by sendingits respective removal tool to a drive unit, and the removal tool wouldalso be capable of removing the previous barrel unit from the driveunit.

Interchangeability of barrel units 117, and particularly, automatedinterchangeability, may allow for rapid configuration andreconfiguration of molding system 100. In particular, different barrelunits may be used with different molding materials, e.g. differentmaterial types or colours. Molding system 100 can therefore bereconfigured for molding parts of different materials by simply swappingbarrel units 117.

Transport Vessels

Details of transport vessels in which molten feedstock may be movedbetween process stations, as associated features at process stationswill now be described, with primary reference to FIGS. 5-12.

FIG. 5 is an enlarged cross-sectional view of an extruder 112 and vessel124 depicting components in greater detail.

Feedstock such as PET pellets is introduced into the cavity of barrel114 and is urged toward outlet orifice 122 by rotation of screw 116.Rotation of screw 116 compresses the feedstock and thereby causesheating and ultimately melting of the feedstock for dispensing into avessel 124.

Extruder 112 includes a nozzle assembly 113 positioned at the dispensingend of barrel 114. As will be explained in further detail, a vessel 124may be positioned opposite nozzle assembly 113 to receive moltenfeedstock. A gate assembly 1130 may be interposed between the extruderand nozzle assembly.

In some embodiments, only a subset of available extruders may beinstalled at any given time. For example, molding system 100 may havefour or more extruders 112 available for use, only a subset of which maybe installed or in active use at any given time.

In such embodiments, each extruder 112 may be used with a specificfeedstock (e.g. a specific combination of colour and material).Conveniently, this may reduce or eliminate the need to change feedstockin any given extruder 112. That is, a switch from a first to a secondfeedstock may be accomplished by removing an extruder containing thefirst feedstock and replacing it with another extruder containing thesecond feedstock. Optionally, the first feedstock may be left in itsextruder 112 for the next time that feedstock is needed. Alternatively,the extruder may be subjected to a cleansing process, which may beautomated, to remove the first feedstock and ready the extruder for itsnext use.

In contrast, changing a feedstock within a specific extruder 112 isrelatively difficult, time consuming, expensive (wasted moldingmaterial) and labour intensive. Typically, the existing feedstock mustbe thoroughly purged from the extruder before a new feedstock can beintroduced.

Vessel 124 is carried by transport subsystem 110 and is positionedadjacent extruder 112 to receive molten feedstock. In the depictedembodiment, vessel 124 is a cartridge with an outer wall 132 defining aninternal cavity 134. Outer wall 132 may be insulated, or may be formedof a material with relatively high thermal resistance. In someembodiments, temperature control elements, such as heating and/orcooling devices, may be mounted to or integrated with wall 132 formaintaining thermal control of feedstock within internal cavity 134.

Vessel 124 may be thermally conditioned such that, prior to receivingmolten feedstock, the vessel has a thermal profile consistent with adesired feedstock temperature. For example, vessel 124 may be heatedprior to receiving feedstock, to limit head loss from the feedstock tovessel 124.

A buffering area may be defined, e.g. within or proximate dispensingcell 102, in which one or more vessels 124 may be collected and preparedfor receiving feedstock, e.g. by thermal conditioning such as heating.Vessels may be carried to and from the buffering area by transportsubsystem 110.

FIGS. 6A and 6B depict isometric and cutaway isometric views,respectively, of a vessel 124. The vessel has a gate orifice 136designed to matingly engage outlet orifice 122 of extruder 112 toreceive flow therefrom. As further described below, in the depictedembodiment, gate orifice 136 also mates to a mold of a shaping station104-1, 104-2, . . . 104-8 to deliver molten feedstock into the mold. Inother embodiments, a separate orifice may be provided for permittingfeedstock to exit vessel 124. In such embodiments, vessel 124 may beconfigured so that feedstock is handled in a first-in first-out manner.That is, the first feedstock that enters vessel 124 through gate orifice136 may also be the first feedstock that is pushed out of vessel 124through an exit orifice. This may limit degradation of material withinvessel 124.

Vessel 124 comprises a barrel 1320 and a tip 1322. Tip 1322 fits overand seals with an end portion of barrel 1320 and the barrel and tipcooperate to define inner cavity 134. Barrel 1320 and tip 1322 may beformed of different materials. For example, barrel 1320 may be formed ofan alloy with high surface hardness for durability. Tip 1322 may beformed of an alloy with high thermal conductivity.

A sealing member 140 (FIG. 6B) is positioned within cavity 134. Sealingmember 140 is operable to control flow through the gate orifice 136.Sealing member 140 is sized to occlude and substantially seal one orboth of extruder outlet orifice 122 and vessel gate orifice 136. Asdepicted, sealing member 140 has a shoulder 1402 that contacts and formsa seal with a corresponding shoulder 1404 of the internal wall of tip1322. Thus, sealing member 140 and tip 1322 may seal against one anotherwith axial facing surfaces, rather than, or in addition to, sealingbetween complementary circumferential surfaces of the vessel gateorifice 136 and an end portion of the sealing member 140. Such axialsealing may be less prone to leakage and wear.

Sealing member 140 includes an elongate stem, also referred to as avalve stem, which is axially moveable relative to the gate orifice 136.Sealing member 140 may be moved by manipulation of the stem.Specifically, sealing member 140 may be retracted away from gate orifice136 to permit flow therethrough, or may be extended to occlude and sealgate orifice 136. In some embodiments, when fully extended, sealingmember 140 may protrude from vessel 124 and into outlet orifice 122 ofextruder 112. In such embodiments, sealing member 140 may form sealswith both of orifices 136 and 122.

Vessel 124 also includes an ejection mechanism for forcing material outof cavity 134. As depicted, the ejection mechanism includes a piston 182received within cavity 134 and movable within the cavity between anextended position in which piston 182 is proximate orifice 136, and aretracted position (shown in FIG. 6B) in which piston 182 is displacedaway from orifice 136 and cavity 134 is occupied by molding material.Piston 182 is configured to seal against the inner wall of vessel 124 asthe piston moves between its extended and retracted positions. Thus,piston 182 may scrape molding material from the inner wall as it movestoward orifice 136.

A thermal regulating assembly 1324 may be positioned over at least aportion of barrel 1320 and tip 1322. As depicted, thermal regulatingassembly 1324 includes a metallic sleeve 1326 and a heating device,namely, heating coil 1328.

In the depicted embodiment, sleeve 1326 is a thermal insulator andinhibits heat loss through underlying surfaces of barrel 1320 and tip1322. Sleeve 1326 may, for example, be formed of an alloy withrelatively low thermal conductivity. In other embodiments, sleeve 1326may serve as a heat sink, such that it tends to promote heat transferout of molding material within cavity 134.

Heating coil 1328 is configured to selectively introduce heat intobarrel 1320 and tip 1322, and thereby, into molding material withincavity 134. Heating coil 1328 may be provided with contacts 1330, whichmay be external to sleeve 1326. Contacts 1330 are configured tointerface with an external power source to activate heating coil 1328.The external power source may be provided at discrete locations. Forexample, contacts 1330 may connect with corresponding contacts at astation of dispensing cell 102, shaping cells 104, 106 or conditioningcell 108, or at a heating station between stations of cells 102, 104,106, 108. Alternatively, contacts 1330 may interface with correspondingpower lines along the length of track 144 such that vessel 124 is heatedcontinuously or throughout a portion of its travel between stations.

Sleeve 1326 and heating coil 1328 may be configured to produce a desiredthermal profile in molding material within cavity 134. Sleeve 1326 ispositioned proximate tip 1322 and the inlet end of barrel 1320, andextends toward the base of vessel 124, i.e. toward the retractedposition of piston 182. In some embodiments, sleeve 1326 does not reachto the retracted position of piston 182. That is, in some embodiments,in the retracted position of piston 182, sleeve 1326 does not overliepiston 182 or the portion of barrel 1320 that surrounds the piston 182.

In an alternative embodiment, not shown, heating of the vessel 124 maybe indirect. For example, the vessels 124 may be induction heated,wherein the vessel includes a heating jacket formed of a suitablematerial, e.g. brass, aluminum, copper or steel, for coupling with anapplied electromagnetic field emanating from a coil located at a heatingstation or otherwise arranged along a path of travel.

In the depicted embodiment, vessel 124 has an insulator 1332 positionedat the end of tip 1322. A cap 1334 fits tightly over insulator 1332.Orifice 136 is cooperatively defined by holes in tip 1322, insulator1332 and cap 1334, which align with one another are which are sized toreceive sealing member 140.

Insulator 1332 is formed of a material selected for sufficientmechanical strength and low thermal conductivity and may be, forexample, plastic, ceramic or metallic. Cap 1334 is formed of a materialselected for relatively high thermal conductivity. As will be explainedin further detail, cap 1334 interfaces with a mold plate of a station ofshaping cell 104, such that cap 1334 is interposed between the mold andtip 1322 of vessel 124. High thermal conductivity of cap 1334 promotesheat transfer from the cap to the mold. Thus, cap 1334 tends to becooler than tip 1322. Cap 1334 cools the distal tip of sealing member140, which in turn promotes solidification of molding material. Thus, atthe end of an injection operation, the relatively cool cap 1334 andsealing member 140 tend to promote solidification of residual materialin orifice 136. Such solidification may allow for clean parting ofmolded articles. Insulator 1332 tends to inhibit heat transfer betweentip 1322 of vessel 124 and mold. Thus, the portion of tip 1322 andinsulator 1332 that surround orifice 136 may remain at a temperatureclose to that of the molten molding material, such that the moldingmaterial experiences a large temperature gradient upon passing throughcap 1334. In some embodiments, cap 1334 may have an internal profileconfigured to limit surface area of contact between cap 1334 and tip1322. For example, cap 1334 may have ridges or castellation (not shown)to locate cap 1334 relative to tip 1322 without continuous contactbetween components.

Tip 1322, insulator 1332, cap 1334, orifice 136 and sealing member 140cooperatively define a coupling assembly for mating of vessel 124 tostations of the dispensing and shaping cells. External features such asthe outer diameter of cap 1334 and the shoulder of tip 1322 engage withcorresponding locating features of the shaping or injecting station toposition orifice 136 in alignment with a mold or extruder. The couplingassembly may also serve to seal vessel 124, e.g. by sealing member 140sealing orifice 136.

In the depicted embodiment, transport subsystem 110 comprises a track144. Vessel 124 is received in a carriage 125, which is slidablyreceived on the track 144. Vessel 124 and carriage 125 may be movedalong the tracks, e.g. by pneumatic or electromagnetic manipulation, orby a mechanical device such as a belt or chain. Transport subsystem 110is capable of precisely indexing the position of each carriage 125mounted to track 144. Thus, transport subsystem 110 may align a specificcarriage 125 and vessel 124 with a specific extruder 112, such that gateorifice 136 of vessel 124 aligns with outlet orifice 122 of extruder112.

Vessel 124 is movable with carriage 125, towards or away from extruder112. In the depicted embodiment, movement of vessel 124 within carriage125 is in a direction perpendicular to track 144. Carriage 125 may havea channel that defines a seat for the vessel and for otherwise defininga path of motion of vessel 124.

Movement of vessel 124 within carriage 125 and operation of sealingmember 140 are affected by an actuator assembly 172.

Actuator assembly 172 includes a vessel positioning actuator, a pistonactuator 176 and a sealing member actuator 178.

With vessel 124 in a dispensing (i.e. filling) position aligned withextruder 112, the vessel positioning actuator is likewise aligned withvessel 124 and is operable to extend into contact with vessel 124 andurge the vessel 124 into engagement with nozzle assembly 113 of extruder112. So engaged, the outlet orifice 122 of extruder 112 and the gateorifice 136 of vessel 124 align in fluid communication with one another.

A piston 182 is movable by piston actuator 176 between an empty positionin which piston 182 is located proximate orifice 136 and a filledposition, in which piston 182 is displaced by feedstock within cavity134. Piston 182 is biased towards its empty position, for example, by aspring or by mechanical force from actuator assembly 172.

Sealing member actuator 178 is operable to engage and retract sealingmember 140 from gate orifice 136, thereby permitting flow of moltenfeedstock through gate orifice 136 and into cavity 134 of vessel 124. Inthe depicted embodiment, sealing member 140 includes a detent 180 forgripping by sealing member actuator 178, such that sealing memberactuator 178 can push sealing member 140 into sealing engagement withgate orifice 136 or withdraw the sealing member 140 to permit flow.

FIGS. 7A-7B show isometric views of vessel 124 and carriage 125.Carriage 125 has a base 1250 configured for mounting to track 144 and aretaining mechanism 1252 for releasably engaging vessel 124 to hold thevessel 124 to the base 1250.

Retaining mechanism 1252 has grips, e.g. tongs 1254 configured tosecurely hold vessel 124. In the depicted embodiment, retainingmechanism 1252 includes two sets of tongs 1254. However, more or fewersets may be present. Tongs 1254 are mounted to a carrier plate 1262,which is in turn mounted to base 1250.

Tongs 1254 are movable between an open position (FIG. 7A) and a closedposition (FIG. 7B). In the closed position, tongs 1254 retain vessel124. Such retention may be achieved, for example, by friction or byinterlocking or a combination thereof. In the depicted embodiment, oneset of tongs 1254 interlocks with a corresponding detent 1255 in thesurface of vessel 124. A second set of tongs 1254 frictionally grips anouter surface of the barrel 1320 of vessel 124. The second set of tongs1254 is positioned above a second detent 1256 in vessel 124. Asexplained in detail below, detent 1256 is for engaging a locatingfeature at a processing station. Tongs 1254 are therefore positioned toavoid interfering with the locating feature. In the open position,clearance is provided between tongs 1254 and vessel 124, such thatvessel 124 can freely pass between or be removed from tongs 1254.

Tongs 1254 may be biased toward a closed position. For example, tongs1254 may be biased by a spring assembly 1260. In some embodiments,spring assembly 1260 may be double-acting such that, when tongs 1254 arepartially opened, e.g. by a threshold amount, spring assembly 1260instead biases tongs 1254 to the open position. Tongs 1254 may beconfigured so that insertion of vessel 124 between tongs 1254 togglestongs 1254 to their closed position. For example, tongs 1254 may have aprofile such that insertion of vessel 124 moves the tongs to anintermediate position between the open and closed positions, in whichspring assembly 1260 biases tongs 1254 to snap to the closed position.The profile of tongs 1254 may be such that they tend to center vessel124 as it is inserted between the tongs. Thus, some horizontalmisalignment of vessel 124 may be tolerated and corrected during seatingof the vessel inside tongs 1254 and closing of the tongs.

Tongs 1254 and carrier plate 1262 are suspended on base 1250 such thatthey have some vertical freedom of movement relative to base 1250. Forexample, tongs 1254 may be free to move vertically to align with detent1255. Such freedom of movement may compensate for vertical mis-alignmentof vessel 124.

Carrier 125 further includes a closure assembly 1270. In the embodimentof FIGS. 7A-7B, closure assembly 1270 is mounted proximate the bottom ofbase 1250.

Closure assembly 1270 has a movable arm 1272, which is movable between asealing position, shown in FIGS. 7A-7B and an open position. In theembodiment of FIGS. 7A-7B, in the sealing position, arm 1272 contacts anend of sealing member 140 and urges it upwardly toward tip 1322 ofvessel 124 to seal orifice 136.

Referring to FIGS. 8A-8D, a sequence of operations for dispensingfeedstock from extruder 112 to vessel 124 is shown in detail. FIG. 8Ashows a side elevation view of part of extruder 112 and vessel 124 priorto engagement thereof. FIG. 8B shows a side elevation view of extruder112 and vessel 124 after engagement and just prior to dispensing offeedstock. FIGS. 8C-8D show longitudinal cross-sectional views ofextruder 112 and vessel 124 prior to and during dispensing.

As shown in FIG. 8A, vessel 124 is held in a carriage 125, movablymounted on track 144. Carriage 125 and vessel 124 are moved on track144, into a dispensing position, between a dispensing nozzle of extruder112 and actuator assembly 172. The vessel positioning actuator (notshown) extends to move vessel 124 into abutment with nozzle assembly 113of extruder 112, as shown in FIG. 8B.

As shown in FIG. 8C, sealing member actuator 178 retracts sealing member140 to permit flow of feedstock from extruder 112 into vessel 124.Piston 182 is displaced away from extruder 112, increasing the volume ofcavity 134, as molten feedstock flows into vessel 124. In the depictedembodiment, vessel 124 has a stop (not shown) which limits displacementof piston 182 and thereby controls the amount of feedstock that ispermitted to flow into vessel 124. The stop may be adjustable.Alternatively, extruder 112 may include a metering mechanism. Forexample, the extruder 112 may include a pumping device for dispensing aspecific preset volume of feedstock. Screw 116 may itself function assuch a pumping device. For example, rotation of screw 116 may becontrolled to dispense a specific volume. Alternatively, screw 116 maybe axially translated to dispense a specific volume.

A dose of feedstock is deposited in vessel 124. The dispensed dose maybe referred to as a workpiece 101. As used herein, workpiece 101 refersto a dose of feedstock throughout its processing in system 100. Primesof the workpiece, i.e. 101′, 101″ denote changes in form of thefeedstock dose as it is processed.

When filling of vessel 124 is complete, sealing member actuator 1748extends sealing member 140 to seal gate orifice 136, as shown in FIG.8C. The vessel positioning actuator then retracts and vessel 124 movesaway from extruder 112 and into carriage 125.

A vessel 124 filled with feedstock material may be transported to ashaping station of shaping cell 104 for a molding operation.

In some embodiments, a gate assembly 1130 may be interposed betweennozzle assembly 113 and vessel 124. FIG. 9 shows an exploded view ofnozzle assembly 113 and vessel 124 with gate assembly 1130. The gateassembly has particular utility when used in combination with a vesselwithout a sealing member 140 (FIG. 8B). Gate assembly 1130 may serve tolocate orifice 136 of vessel 124 with nozzle assembly 113. Gate assembly1130 may further serve to cut a stream of feedstock between nozzleassembly 113 and vessel 124 when filling of vessel 124 is complete.

Gate assembly 1130 includes a guide block 1132 and a blade 1134. Guideblock 1132 has respective recesses 1136 for receiving and aligning eachof nozzle assembly 113 and the tip of vessel 124. Blade 1134 can beextended through a pocket in guide block to cut off a stream offeedstock. As depicted, blade 1134 has an arched cross-sectional shapeand is compressed within the pocket of guide block 1132 such that blade1134 is biased against nozzle 113. A scraper 1133 is positioned opposingblade 1134, such that scraper 1133 contacts blade 1134 to dislodgemolding material from the blade.

Blade 1134 may be extended to cut off a stream of feedstock when fillingof vessel 124 is complete. FIGS. 10A-10B are enlarged cross-sectionalviews of nozzle assembly 113, vessel 124 and gate assembly 1130 duringcutting of a feedstock stream.

As shown in FIG. 10A, a stream of feedstock is dispensed from nozzleassembly 113 into vessel 124 through orifice 136. When filling of vessel124 is complete, blade 1134 is advanced toward the stream.

As shown in FIG. 10B, blade 1134 is biased against nozzle assembly 113.As blade 1134 is advanced into the feedstock stream, blade 1134 partsthe stream. Blade 1134 fits tightly against nozzle assembly 113 suchthat feedstock is substantially prevented from leaking between blade1134 and nozzle assembly 113. Blade 1134 has a tab 1138 which extendsdownwardly into contact with vessel 124. As blade 1134 advances acrossvessel 124, tab 1138 scrapes feedstock away to limit or eliminateresidue on the exterior of the vessel.

Primary Shaping

With primary reference to FIGS. 11-24, features and operation of examplestations of snapping cell 104 will now be described in detail. In thedepicted embodiments, the example stations are for injection molding ofplastic articles. However, many features of the described embodimentsare not limited to injection molding, as will be apparent.

FIGS. 11-12 show an enlarged isometric view and a side cross-sectionalview, respectively, of a shaping station 104-1 of shaping cell 104.Shaping station 104-1 cycles between an open state for discharging amolded workpiece and a closed state for receiving a dose of feedstock toform a molded workpiece 101′. As shown in FIGS. 11-12, shaping station104-1 is in an open state.

Shaping station 104-1 has a mold defined by a core assembly 190 and acavity assembly 192. Cavity assembly 192 has two cavity plates 194-1,194-2 (individually and collectively, cavity plates 194), mounted toplatens 196-1, 196-2 (individually and collectively, platens 196).Platen 196-1 is mounted to a clamping mechanism, such as a hydraulic orelectro-mechanical piston. Platen 196-1 is movable relative to platen196-2, the latter of which is fixedly mounted to a base structure.

As shown in FIG. 12A, in the open state of shaping station 104-1, platen196-1 is withdrawn from platen 196-2. Cavity plate 194-2 is aligned witha mold axis M-M and core assembly 190 is aligned with an ejection axisE-E.

FIGS. 12B-12D depict components of shaping station 104-1 in greaterdetail. In the depicted example, shaping station 104-1 includes a moldsubassembly 3040, a clamp subassembly 3042 and a core actuationsubassembly 3044, the latter of which includes a core positioningactuator 3046 and a load actuator 3050. For simplicity, core actuationassembly is omitted from FIG. 12D.

Each of mold subassembly 3040, clamp subassembly 3042 and core actuationsubassembly 3044 are mounted to a shaper frame 3052. Mold subassembly3040, clamp subassembly 3042, core actuation subassembly 3044 and shaperframe 3052 collectively define a shaper module 3054. The shaper frame3052 may be removably mounted to a support base 3056 of shaping station104-1, such that shaper module 3054 may be installed or removed as aunitary assembly.

As best shown in FIG. 12C, mold subassembly 3040 may be opened andclosed along multiple axes. That is, platens 196, with cavity plates194, may be opened and closed along a clamping axis C1-C1. Core assembly190 may be moved towards or away from cavity plates 194 along core axisC2-C2. Opening and closing along clamping axis C1-C1 may be affected byclamp subassembly 3042. Movement of core assembly 190 along core axisC2-C2 may be affected by core actuation subassembly 3042.

FIG. 12D shows details of coupling between clamp subassembly 3042 andshaper frame 3052. For simplicity, core actuation subassembly 3044 isomitted from FIG. 12D.

Platens 196 may be supported by shaper frame 3052. Platens 196 andshaper frame 3052 may have mating guide features which maintain positionand alignment of platens 196 during opening and closing. In the depictedembodiment, the guide features include guide rails 3062 on shaper frame3052 which matingly receive pins (not shown) on platens 196. In otherembodiments, the guide features may be interlocking tracks. Other guidestructures are possible, as will be apparent.

As depicted, platen 196-1 is slidably mounted to support frame 3052using the guide features. Platen 196-2 is rigidly mounted to supportframe 3052 in a fixed position. In this embodiment, clamp subassembly3042 causes opening and closing by movement of platen 196-1 relative toplaten 196-2 along clamping axis C1-C1. In other embodiments, openingand closing is achieved by movement of both platens toward and away fromone another.

Clamp subassembly 3042 includes a multi-bar linkage 3070. Linkage 3070includes an anchor block 3072 rigidly mounted to support frame 3052, anda plurality of pivotably-connected links coupling a platen 196 to theanchor block 3072. In the depicted embodiment, the links include a drivelink 3074 and first and second rockers 3076, 3078. Drive link 3074 iscoupled to a crosshead 3080.

Crosshead 3080 may be reciprocated by a suitable linear actuator, suchas a ballscrew. Drive link 3074 may pivot relative to crosshead 3080 andrelative to rockers 3076, 3078 as the crosshead moves through itsstroke, likewise causing rockers 3076, 3078 to pivot relative to oneanother to drive platen 196 in either direction along clamping axisC1-C2.

Clamp subassembly 3042 has a plurality of pivotable connections 3082,each of which may be formed by press-fitting a pin and a bushing (notshown) through holes in the links or in support frame 3052. Otherconnection types may be used, provided they have sufficient strength andprovide adequate range of motion.

Anchor block 3072 is mounted to support frame 3052 such that the centeraxis of anchor block 3072 aligns with the center axis of support frame3052. Guide rails 3062 maintain the position of platen 196 such that thecenter axis of platen 196 aligns with the center axis of support frame3052. Thus, anchor block 3072 and platen 196 are coupled to linkage 3070at me center axes or anchor block 3072, platen 196 and support frame3052. In other words, pivotable connection 3082 between the anchor block3072 and rocker 3076 is located along the center axis of anchor block3072 and along the center axis of support frame 3052. Likewise,pivotable connection 3082 between platen 196 and rocker 3078 is locatedalong the center axis of anchor block 3072 and along the center axis ofsupport frame 3052.

Movement of crosshead 3080 causes platens 196 to move between open andclosed positions. In the closed (molding) position, a clamping force maybe applied through crosshead 3080 and linkage 3070 to urge the platenstogether. The clamping force may be substantial—in some embodiments, theclamping force may be on the order of 300 kN. As will be apparent, areaction force is applied to support frame 3052. In the depictedembodiment, platen 196 and anchor block 3072 are loaded substantially inpure compression, and that support frame 3052 is loaded substantially inpure tension because linkage 3979 is coupled to platen 196 and anchorblock 3072 at the center axis of platen 196, anchor block 3072 and frame3052. In contrast, location of any of the pivotable connections awayfrom the center of a given component could produce significant shearforce or bending moment. For example, platens in conventional injectionmolding machines tend to be closed by rams (e.g. hydraulic rams or ballscrews) positioned proximate the corners of a platen. Exerting ofclamping force in such configurations may produce a bending moment inthe platens and may in some cases lead platens to deflect.

In some embodiments, the stroke length between the open and closedpositions of platen 196 is relatively short. The length of the stroke isinfluenced by the amount of clearance required to remove (de-mold) afinished part. De-molding may be possible with a relatively smallopening along an axis perpendicular to the longitudinal axis of thepart. Thus, some example embodiments have a mold-opening stroke on theorder of 60-120 mm. Conversely, if parts were to be de-molded by openingalong the longitudinal axis of the part, a longer opening stroke may berequired, to create a larger amount of clearance.

Other linkage configurations are possible. For example, in someembodiments, the linkage may include one or more rockers which arepivotably connected to support frame 3052. FIGS. 13A-13C show a linkage3070′ exemplary of such a configuration.

Linkage 3070′ has a drive link 3074′ anchored to a linear actuator 3088(as shown, a ball screw driven by an electric motor) with one or moreintermediate links 3086. Drive link 3074 is mounted on a linear guide3090. As depicted, the linear guide constrains drive link 3074′ to movein a single direction, namely, vertically. Specifically, linear actuator3088 reciprocates horizontally, and intermediate links 3086 pivot tomove the drive link through reciprocating vertical path I-I defined bylinear guide 3090 (FIG. 13B).

Drive link 3074′ is pivotably connected to two rockers 3076′, 3078′ byway of further intermediate links 3086. Each rocker 3076′, 3078′ ismounted to a respective platen 196 for driving the platen through areciprocating open-close motion. Each rocker 3076′, 3078′ is pivotablymounted to support frame 3052. Reciprocation of drive link in directionI-I (FIG. 13B) causes rockers 1-76′, 3078′ to pivot about theirconnection to support frame 3052, i.e. in direction II-II. Such pivotingin turn drives reciprocation of platens 196 along direction III-III. Theposition and orientation of platens 196 during such reciprocation ismaintained by guide rails 3062 on support frame 3052.FIG. 13C shows anexample loading state of linkage 3070′ and support frame 3052 whenplatens 196 are in a mold-closed position. As depicted, drive link 3074′applies a force to rockers 3076′, 3078′. The rockers 3076′, 3078′ pivotto around their connections to drive platens 196 together and apply aclamping force against the platens. Because rockers 3076′, 3078′ pivotabout their midpoints, the clamping force and the force applied by drivelink 3074 are substantially equal in magnitude. Equal reaction forcesare applied against rockers 3076′, 3078′, which are resisted by supportframe 3052. Transfer of forces between rockers 3076′, 3078′ and supportframe 3052 occurs at pivotable connections 3082, which are located atthe center axis of support frame 3052. Accordingly, application ofclamping force loads support plate 3052 substantially in pure tension.

The length of the opening/closing stroke of platens may be determined bygeometric specifications of linkage 3070′. Specifically, the stroke maybe determined by a combination of the lengths of drive link 3074′,rockers 3076′, 3078′, intermediate link 3086, and the length of strokeof linear actuator 3088.

In some embodiments, the linkage may be configured to maintain positionand alignment of platens 196 without the use of guiding structures suchas guide rails 3082. FIGS. 14A-14B show an example of one such linkage3070″.

Linkage 3070″ is generally identical to linkage 3070′, except thatlinkage 3070″ further includes secondary rockers 3096, 3098, and thatsupport plate 3052′ is somewhat larger than support plate 3052 in orderto accomodate the extra rockers.

Secondary rocker 3096 cooperates with rocker 3076′ to control a firstplaten 196 and secondary rocker 3098 cooperates with rocker 3078′ tocontrol a second platen 196. Each pair of rockers constrains theposition and alignment of platens 196 during opening and closing.Secondary rockers 3096 and 3098 are connected at one end to drive link3074′ and at the other end to an intermediate link 3086, which is alsoconnected to the corresponding rocker 3076′/3078′ and to a platen 196.The multiple connections between platens 196 and support frame 3052 holdplatens 192 square to support frame 3052 and to one another. Likewise,rockers 3076′/3078′ and secondary rockers 3096/3098 cooperate to alignthe positions of platens 196 at the end of the closing stroke.

In some embodiments, the clamp assembly 3042 may be driven by a rotaryactuator rather than a linear actuator. For example, clamp assembly 3042may be driven by the crank of an electric motor. FIGS. 15A-15B show alinkage 3070′″ exemplary of such an embodiment. Linkage 3070′″ isgenerally similar to linkage 3070′, but drive link 3074′ is replaced bya rotor 3100. Rotor 3100 is driven by a crank shaft, e.g. a crank shaftof an electric motor. Rotor 3100 may be coupled to the crank shaft byway of a gearset, such as a planetary gearset, to provide a suitablespeed reduction.

Rotor 3100 is driven to rotate around its midpoint, and the ends ofrotor 3100 are coupled to rockers 3076′, 3078′ by way of intermediatelinks 3086, such that rotation of rotor 3100 causes rockers 3076′, 3078′to pivot about their connections 3082 to support frame 3052. When themold is closed and clamping pressure is applied to platens 196, rockers3076′, 3078′ and support frame 3052 are subjected to a loading conditionsimilar to that of FIG. 13C. That is, the clamping force is equivalentto the force exerted on rockers 3076′, 3078′ by rotor 3100 andintermediate links 3086, and support frame 3052 is loaded substantiallyin pure tension.

Linkage 3070′″ may be relatively easily adjustable. For example, thelength of rotor 3100 and its associated intermediate links 3086 may bechanged to adjust the length of the opening/closing stroke of platens196. Increasing the length of rotor 3100 may increase the stroke.Clamping force may be adjusted by changing the length of rockers 3076′,3078′ or by changing the torque applied to rotor 3100 (e.g. by changingratio of the set to which it is coupled). Accordingly, linkage 3070′ maybe relatively easily adapted for use with a range of molds.

Embodiments may include combinations of features of the above-describedcrank assemblies and linkages. For example, FIG. 16 shows a linkagewhich includes a crank-driven clamp assembly and has multiple rockersconnected to each platen to provide positional stability.

In the embodiments depicted in FIGS. 12-15, rockers 3076′, 3078′ aremounted to support frame 3052 at their midpoint, so that they rotatesymmetrically. In some embodiments, the pivot point may be off-center.For example, the pivot point may be moved closer to the driven end ofthe rockers 3076′, 3078′ in order to increase the clamping force or toincrease the length of the opening-closing stroke. Conversely, the pivotpoint may be moved closer to the opposite end to decrease the clampingforce or stroke length.

As depicted in FIGS. 13-16, linkages 3070′, 3070″ and 3070′″ of clampsubassembly 3042 act on both platens 196 to move them towards and awayfrom one another. In other embodiments, the clamp subassembly may beconfigured to act on a single movable platen 196, while the other platen196 is fixed. For example, drive link 3074′ or rotor 3100 may be coupledto only a single rocker and platen 196.

With reference to FIGS. 17, 18A-18B, 19, 20 and 21A-21B, components ofcore actuation subassembly 3044 are shown in greater detail. Coreactuation subassembly 3044 is configured to move core assembly 190 alonga core axis. In the depicted embodiment, core actuation subassembly 3044comprises a core positioning actuator 3046 operable to move coreassembly 190 through a first stroke between molding (closed) andde-parting (open) positions. Core positioning actuator 3046 may bemounted to a secondary mold opening actuator 3180. Core actuationsubassembly 3044 further comprises a load actuator 3050 operable toexert force on core assembly 190 and move core assembly 190 through ashorter stroke to initiate de-parting after molding and to resistmolding forces. FIGS. 18A-18B show isometric and cross-sectional views,respectively, of core positioning actuator 3046.

Core positioning actuator 3046 has a primary frame 3102 for securing tosupport frame 3052. Core positioning actuator further includes a loadingframe 3104 positioned atop primary frame 3102. In the depictedembodiment, loading frame 3104 is mounted to primary frame 3102 usinglocating pins, such that loading frame 3104 may be moved verticallyrelative to primary frame 3102 while maintaining alignment.

Core positioning actuator 3046 may include one or more pneumatic pistons3108 for moving loading frame 3104 relative to primary frame 3102. Asbest shown in FIG. 18B, pneumatic pistons 3108 are mounted to loadingframe 3104 and act against primary frame 3102 to move loading frame 3104towards or away from primary frame 3102. As depicted, pistons 3108 arecoupled to an intermediate structure, namely pins 3110. In otherembodiments, pistons 3108 may be coupled directly to primary frame 3102.Two hydraulic pistons 3108 are shown in FIG. 18B, however, any number ofpneumatic pistons may be present. In some embodiments, other suitablelinear actuators may be used instead of or in addition to pneumaticpistons. Primary frame 3102 has a central opening sized to receive coreassembly 190. Core assembly 190 is mounted to loading frame 3104 andextends through the central opening. Core assembly 190 includes an innercore 3112 and an outer core 3114. During molding, inner core 3112defines the inside surface of the part to be molded. Outer core 3114seals the top of the mold defined by core assembly 190 and cavityassembly 192.

Inner core 3112 is mounted to loading frame 3104 and is received withinouter core 3114 such that inner core 3112 is movable relative to outercore 3114. Specifically, inner core 3112 is movable relative to outercore 3114 along the core axis by motion of loading frame 3104. Outercore 3114 is fixedly mounted to primary frame 3102 by a retainingassembly 3116 which engages a flange 3118 of the outer core. Thus,relative movement of frames 3102, 3104 likewise causes relative movementof inner and outer cores 3102, 3104. After molding of a part, loadingframe 3104 may be moved away from primary frame 3102, causing retractionof inner core 3112 to release the molded part.

A locating pin assembly 3120 is positioned on primary frame 3102 toalign loading frame 3104 and primary frame 3102 (and thus, to aligninner core 3112 with outer core 3114 and core assembly 190 with centralopening 3106).

Locating pin assembly 3120 includes a pin 3122 and a pneumatic piston3124. When loading frame 3104 is spaced apart from primary frame 3102,piston 3124 may extend pin 3122. Loading frame 3104 may have a recess(not shown) sized and positioned for registration with pin 3122. Thus,when loading frame 3104 is lowered against primary frame 3102 formolding, pin 3122 may register with the recess, guiding frame 3104 intoproper alignment.

Referring again to FIG. 18A, loading frame 3104 defines an interlockingaperture 3130. Locking aperture 3130 is sized and positioned to engage acorresponding interlocking feature of loading actuator 3050.

FIG. 19 depicts loading actuator 3050 in greater detail. Loadingactuator 3050 includes a base plate 3140 and a moving plate 3142. Movingplate 3142 is movable relative to base plate 3140 and one or more guiderods 3144 are mounted to base plate 3140 and received in correspondingopenings in moving plate 3142 to guide motion of the moving plate.

Loading actuator 3050 has a drive assembly 3146 comprising a motor 3148,gearset 3150, and rocker 3152. Motor 3148 is coupled to rocker 3152through gearset 3150 and a camshaft 3154 to cause rotation of and imparttorque on rocker 3152. Moving plate 3142 is mounted to one end of rocker3152 and base plate 3140 is mounted to the other end of rocker 3152.

Rocker 3152 may be rotated by motor 3148 through gearset 3150 andcamshaft 3154 to move moving plate 3142 relative to base plate 3140.Guide rods 3144 constrain the movement to a vertical axis, i.e. coreaxis.

FIG. 20 is a cutaway view of load actuator 3150 showing coupling ofmotor 3148, gearset 3150 and camshaft 3154, to move rocker 3152 andplates 3140, 3142 in greater detail. As depicted, a camshaft 3154 issupported on moving plate 3142. Camshaft 3154 is received through oneend of rocker 3152. Ends of camshaft 3154 are received in fittings 3155in movable plate 3142. Rocker 3152 supports moving plate 3142 by way ofcamshaft 3154 and fittings 3155.

The opposite end of rocker 3152 is mounted to base plate 3140 by aretainer shaft 3160. Retainer shaft 3160 is received by a pair of blocks3162 which are rigidly fixed to base plate 3140.

Camshaft 3154 is supported by bearings 3164 within rocker 3152 andwithin fittings 3155. Likewise, retainer shaft 3160 is supported bybearings 3166 within blocks 3162. Camshaft 3154 and retainer shaft 3160may therefore rotate relative to plates 3140, 3142 with relativelylittle resistance.

Camshaft 3154 is rotationally coupled to gearset 3150 (not shown) by wayof a coupling 3156. Gearset 3150 may be configured to drive camshaft torotate with relatively low speed and relatively high torque. Camshaft3154 has an offset lobe such that the radius to from the center ofrotation of shaft 3154 to the outside of its offset lobe is greater thanthe radius from the center of rotation to any other part on theperiphery of the crankshaft. As crankshaft 3154 turns with gearset 3150,its offset lobe engages with a bearing 3166 within rocker 3152. As theoffset lobe falls, camshaft 3154 bears against rocker 3152 and urgesmoving plate 3142 upwardly. As the offset lobe falls, rocker 3152 andmoving plate 3142 are allowed to fall.

As shown in FIG. 19, a measurement device, namely, proxy bracket 3170may be installed to provide an indication of the position of camshaft3154. Proxy bracket 3170 is fixed to base plate 3140 and extendsupwardly past camshaft 3154. A sensor 3172 is mounted to proxy bracket3170 and provides a signal representative of the rotational position ofcamshaft 3154. Alternatively or additionally, a sensor may provide asignal representative of the vertical position of moving plate 3142.Alternatively or additionally one or more position transducers could bemounted between base plate 3140 and moving plate 3142 to provide asignal representative of the relative positions of the plates.

As best shown in FIGS. 19 and 21A-21B, moving plate 3142 has projections3174 for engaging loading frame 3104 of core positioning actuator 3046.Projections 3142 are sized, shaped and positioned for engagement withinterlocking recess 3130 defined by loading frame 3104. With the mold ina closed position, projections 3174 are received in recess 3130.Projections 3174 have upward-facing surfaces 3176 which abutcorresponding surfaces of loading frame 3104 in the mold-closedposition. In the depicted embodiment, upward-facing surfaces 3176 areinclined, such that they may bear on the corresponding surfaces ofloading frame 3104 during closing and guide the projections 3174 intomating alignment with the recess 3130. Projections 3174 further includedownward-facing surfaces 3178 which abut corresponding faces of loadingframe 3104.

Movement of moving plate 3142 while projections 3174 are received inapertures 3130 causes projections 3174 to bear against frame 3104.Specifically, upward movement of moving plate 3142 causes surfaces 3176to bear against frame 3104, urging the frame upwardly. Downward movementof moving plate 3142 causes surfaces 3178 to bear against frame 3104,urging the frame downwardly.

Rotation of camshaft 3154 may therefore selectively cause an upward ordownward force to be exerted against frame 3104, in turn causing frame3104 to move through a short stroke. Rotation of camshaft 3154 to urgeplate 3142 upwardly by way of rocker 3152 (FIG. 20) causes a shortupward movement of frame 3104, and therefore, a short upward movement ofinner mold core 3112 (FIG. 18B). Such upward movement may serve todislodge or break a seal between a molded part and mold core 190.

The depicted configuration may eliminate the need for a separatestripper plate to remove molded articles, and may thus reduce mechanicalcomplexity of the molding apparatus relative to a typical configurationincluding a stripper plate.

Rotation of camshaft 3154 to urge plate 3142 downwardly by way of rocker3152 (FIG. 20) causes a downward force to be exerted on frame 3104 and ashort downward movement of frame 3104. The force and short movement aretransferred to inner mold core 3112 and may function as a pre-load toresist pressure exerted by molding material against mold core 190 duringmolding.

Core positioning actuator 3046 may be mounted to one of platens 196.Loading actuator 3050 may be mounted to the other of platens 196.Loading actuator 3050 may be rigidly mounted, such that base plate 3140does not move relative to the platen 196 to which it is mounted.

Core positioning actuator 3046 may be mounted by way of a secondary moldopening actuator 3180, shown in FIGS. 17 and 22. Secondary mold openingactuator 3180 includes one or more blocks 3182 rigidly mounted to aplaten 196. Secondary mold opening actuator 3180 further includes apneumatic cylinder 3186 carried on a plate 3184 mounted to the block3182. Pneumatic cylinder 3186 has a coupling 3190 for fixation toprimary frame 3102 of core positioning actuator 3046. Pneumatic cylinder3186 is operable to move core positioning actuator between a retractedposition in which the mold core 190 is located in its molding positionrelative to the mold cavity portions, and an extended position in whichit is spaced apart from the mold cavity portions for removal of moldedparts.

As noted, shaper module 3054 may be capable of installation or removalfrom support base 3056 of shaping station 104-1 as a unitary assembly.Installation and removal features of shaper module 3054 are shown ingreater detail in FIGS. 23A-23C.

In the depicted embodiment, the shaper module 3054 includes a driveunit, namely, electric motor 3190. When installed in an operationalposition, there may be insufficient clearance between components ofshaper module 3054 and support base 3056 to remove shaper module 3054.Likewise, there may be insufficient clearance to remove mold components.Accordingly, shaper module 3054 includes a position adjustment mechanism3192 operable to move the shaper module 3054 relative to support base3056 along an adjustment axis indicated as A-A in FIG. 23A. Shapermodule 3054 may be moved between an operational position, as depicted inFIGS. 12A-12D, and a removal position, in which shaper module 3054 canpass without interference through a removal opening 3194 defined bysupport base 3056. As depicted, adjustment axis A-A is parallel to thelongitudinal axis of shaper frame 3052. However, in some embodiments,shaper module 3054 may be adjustable along a different axis, or alongmultiple axes. Likewise, in the removal position, a mold may be removedand replaced. That is, the mold may be removed from shaper modulewithout contacting support base 3056. Accordingly, such removal andreplacement may be affected automatically, e.g. using a robot

Once in its removal position, shaper module 3054 may be removed frombase 3056. For example, a lifting tool such as a crane or a lift truckmay engage couplings on shaper module 3054. In an example, the couplingsmay be hooks rigidly mounted to shaper frame 3052 for secure engagementby a crane. The lifting tool may remove the snapper module by verticalor horizontal translation or a combination thereof.

As shown in FIG. 23C, support base 3056 may include one or more guideblocks 3196 for locating the shaper module 3054 in its operationalposition. Shaper module 3054 may include corresponding locking pins3195, rigidly mounted to shaper frame 3052. Locking pins 3195 mayselectively engage guide blocks 3196 to prevent movement of shapermodule 3054 relative to support base 3056. Locking pins may be operated,for example, by an electric motor or using manual tools. Other modes ofactuation are possible, such as pneumatic.

FIG. 23C shows adjustment mechanism 3192 in greater detail. As depicted,adjustment mechanism has a linear actuator, such as ballscrew 3197,positioned between two anchor plates 3198. One anchor plate 3198 abutssupport base 3056 and the other is rigidly coupled to shaper frame 3052.Actuation of the ballscrew 3197 in a first direction pushes the anchorplates 3198 away from one another, such that shaper module 3054 movesrelative to support base 3056 in a first direction along the adjustmentaxis. Actuation of the ballscrew 3197 in the opposite direction movesshaper module 3054 relative to support base 3056 in the oppositedirection along the adjustment axis.

In some embodiments, adjustment mechanism 3192 may be configured suchthat shaper module is in its operational position at either the maximumextension or the minimum extension of ballscrew 3197, and the shapermodule 3054 is in its removal position at the other of the maximumextension and the minimum extension of ballscrew 3197. Alternatively oradditionally, adjustment mechanism may be equipped with a sensor toreport the position of shaper module 3054 to confirm when it is in itsoperational and removal positions. For example, ballscrew 3197 may bedriven by an electrical motor with a position encoder, or the positionmay be measured by a sensor such as an optical, mechanical or magneticsensor.

Installation and removal of shaper module 3054 as a unitary assembly maypermit relatively easy changes of tooling in shaping station 104-1. Forexample, if it is desired to change a mold, the associated clampingassembly, drive unit and core actuation assembly may be removed as aunit with the mold, and a new unit may be installed to base 3056.Mold-specific setup may be minimized or eliminated entirely. Forexample, because a clamping assembly may remain assembled to a moldafter removal from base 3056, it could be reinstalled without requiringadjustments for mold shut height or the like.

In the closed state of shaping station 104-1 (FIG. 12B, FIGS. 29B-29F),core assembly 190 is aligned to axis M-M and cavity plates 194-1, 194-2are clamped together by platens 196-1, 196-2. Core assembly 190 andcavity plates 194-1, 194-2 collectively form a mold 200 for producing amolded workpiece from molten feedstock material. Core assembly 190defines an inner surface of the molded workpieces. Cavity plates 194-1,194-2 collectively define the outer surface of the molded workpiece.Mold 200 has an inlet gate 202, aligned with axis M-M.

Track 144 of transport subsystem 110 passes through an injectionposition aligned with mold axis M-M.

FIGS. 24A-24T depict an alternate shaper module 3054′. As shown in FIGS.12-23, shaper module 3054 is configured so that mold opening and closingis affected by linkage 3070, 3070′, 3070″, 3070′″ pivoting about ahorizontal axis. As depicted in FIGS. 24A-24L, shaper module 3054′ isconfigured so that its linkage generally lies in a horizontal plane andpivots about a vertical axis.

Shaper module 3054′ is supported by a tower structure 7000, depicted ingreater detail in FIGS. 24C-24F Shaper module 3054′ has a support plate3052′ that is structurally identical to the support plate of shapermodule 3054, except that it is mechanically suspended on tower structure7000 and is oriented in a vertical plane.

Shaper module 3054′ has a mold subassembly 3040′, a clamp subassembly3042′ including a linkage 3070′″, and a core actuation subassembly3044′.

Like mold subassembly 3040, mold subassembly 3040′ may be opened andclosed along multiple axes, namely, vertical and horizontal axes.Specifically, platens 196 and mold cavity plates 194 open and closealong clamping axis C1-C1 and core assembly 190 is movable along coreaxis C2-C2. In the depicted embodiment, core axis C2-C2 is vertical.Accordingly, with reference to this embodiment, “up” refers to adirection along core axis C2-C2 away from mold cavity plates 194, and“down” refers to a direction along core axis C2-C2 toward cavity plates194. However, other orientations of shaper module 3054′ are possible.For example, in some embodiments, shaper module 3054′ could be rotated90 degrees such that clamping axis C1-C1 and core axis C2-C2 lie in acommon horizontal plane.

Mold cavity plates 194 and mold core 190 lie within a bounding envelopeE between platens 196. The ends of the bounding envelope are defined byplatens 196. The top and bottom of the bounding envelope are defined bythe top and bottom edges of platens 196, and the lateral sides of thebounding envelope are defined by the sides of platens 196.

Throughout molding and throughout movement of platens 196 through theiropening-closing stroke, mold cavity plates 194 lie entirely within thebounding envelope.

The tower structure 7000, shaper frame 3052′, and linkage 3070″″ arelocated on one side of bounding envelope E. That is, all of the towerstructure 7000, shaper frame 3052′ and linkage 3070″″ are adjacent thesame lateral side of bounding envelope E. Conveniently, the oppositelateral side of bounding envelope E is substantially unobstructed, as isthe bottom of bounding envelope E.

FIG. 24B is a top elevation view of shaper module 3054′, showing linkage3070″″ in greater detail. Linkage 3070″″ includes a pair of drive links3074 and rockers 3076, 3078.

Each drive link 3074 is pivotably supported at one end by tie bars 7002of tower structure 7000, and is pivotably connected at the other end toa rocker 3076 or 3078. Drive links 3074 are coupled to and reciprocatedthrough a stroke by a drivetrain 7006. Drivetrain 7006 is supported ontower structure 7000 and may include an electric motor and one or moregear reductions.

Each of rockers 3076, 3078 is pivotably attached to one of drive links3074 at one end, and to a respective platen 196 at the other end. In thedepicted embodiments, rockers 3076, 3078 are connected to platens 196 byway of intermediate links 3086. Rockers 3076, 3078 are supported on tiebars 7002 of tower structure 7000 at pivotable connections 3082, so thatdrive links 3074 cause rockers 3076, 3078 to rotate around pivotableconnections 3082. As depicted, pivotable connections 3082 areapproximately at the mid-point of rockers 3076, 3078, but could belocated at a different positions along the length of the rockers. Movingthe pivotable connection 3082 toward the connection with drive link 3074would result in a longer stroke of platen 196 while the rocker isrotated. Conversely, movement of the pivotable connection 3082 away fromthe drive link 3074 would result in a shorter stroke of platen 196.

FIGS. 24C-24F depict tower structure 7000 in greater detail. FIG. 24C isan isometric view of shaper module 3054′ from a rear perspective,opposite the mold. FIG. 24D is an isometric view of shaper module 3054′from a front perspective, with components other than tower structure7000 and shaper frame 3052′ omitted. FIGS. 24E, 24F are cross-sectionalviews of tower structure 7000 along planes E-E and F-F shown in FIG.24B.

Tower structure 7000 includes a pair of vertical columns 7010. Columns7010 are supported on a base (not shown) and bear the weight ofcomponents of tower structure 7000 and of mold assembly 3040′, clampingassembly 3042′ and core actuation assembly 3044′.

Shaper frame 3052′ is coupled to columns 7010 by way of mounting blocks7012. Shaper frame 3052′ is oriented in a vertical plane. Tracks 7024are mounted to shaper frame 3052′. Tracks 7024 are configured toslidably support platens 196. Tracks 7024 are oriented in a verticalplane, such that connections between platens 196 and shaper frame 3052′are likewise in a vertical plane.

As will be apparent, platens 196 hang on tracks 7024. Tracks 7024 aretherefore configured to interlock with platens 196 in order to retainthe platens. For example, platens 196 may have runners withcross-sectional shapes that interlock with the cross-sectional shapes oftracks 7024.

Tower assembly 7000 further includes tie bars 7002. Components oflinkage 3070″″ of clamping assembly 3042′ are coupled to tie bars 7002.For example, drivetrain 7006 is partly supported by tie bars 7002. Arotor 7007 of drivetrain 7006, which is directly coupled to drive links3074, is rotatably mounted between tie bars 7002. Rockers 3076. 3078 arealso rotatably mounted between tie bars 7002. Pivotable connections 3082at which rockers 3076, 3078 are connected to tie bars 7002, permitrotation of the rockers, but substantially prevent translation of therockers in any direction. Thus, stresses such as tensile or compressivestresses may be transferred between the rockers and the tie bars.

In the depicted embodiment, tie bars 7002 are not coupled directly tocolumns 7010. Rather, tie bars 7002 are mounted to a support block 7020.As shown in FIGS. 24E-24F, support block 7020 is positioned between tiebars 7002, abutting both of tie bars 7002 and shaper frame 3052. Supportblock 7020 braces tie bars 7002 relative to one another and relative toshaper frame 3052′. Fasteners 7022 are inserted through tie bars 7002and received in support block 7020 to secure the tie bars against thesupport block. A second set of fasteners 7024 is inserted through shaperframe 3052′ to secure the tie bars against shaper frame 3052′. As noted,shaper frame 3052′ is in turn coupled to towers 7010 by way of mountingblocks 7012. Thus, tie bars 7002 are coupled to shaper frame 3052′ byway of support block 7020, and to columns 7010 by way of support block7020 and shaper frame 3052.

FIGS. 24G, 24H are cut-away and cross-sectional views, respectively,showing details of mold assembly 3040′, clamping assembly 3042′ and coreactuation assembly 3044′.

Mold assembly 3040′ has a pair of platens 196 movable by linkage 3070toward and away from one another in a closing stroke and an openingstroke, respectively. Platens 196 are supported on tracks 7024 on shaperframe 3052. Platens 196 and tracks 7024 may be configured to interlock,such that platens 196 hang securely from tracks 7024, and can movefreely along the tracks. For example, platens 196 may have runners whichinterlock with the tracks.

A mold cavity plate 194 is mounted to each platen. With platens 196 in amold-closed position (FIG. 24A), mold cavity plates 194 abut one anotherto cooperatively define a mold cavity.

During molding, rockers 3076, 3078 exert a clamping pressure on platens196 and mold assembly 3040′ by way of intermediate links 3086. Clampingpressure generally acts along clamping axis C1-C1. A reaction force isapplied to tie bars 7002 by way of rockers 3076, 3078 at pivotableconnections 3082. This in turn causes a load to be transferred to shaperframe 3052′ at pivotable connections 3082.

Because linkage 3070″″ is symmetrical, equal forces are applied toshaper frame 3052′ by rockers 3076, 3078. Shaper frame 3052′ experiencesstrain due to the tensile force applied by the rockers. That is, shaperframe 3052′ tends to elongate in the direction of clamping axis C1-C1due to tension.

In contrast, columns 7010 generally do not deflect during molding.Shaper frame 3052′ is therefore coupled to columns 7010 so as to limitthe deflection of shaper frame 3052′ relative to columns 7010 at thepoints of attachment.

For example, elongation of shaper frame 3052′ due to tensile stressduring clamping is most pronounced at the ends of shaper frame 3052′. Inother words, a feature at an end of shaper frame 3052′ may move morebetween stressed and un-stressed conditions of shaper frame 3052′ thanwould a feature located at the center of shaper frame 3052′.

Thus, fasteners 7024 couple shaper frame 3052 to support block 7020 nearthe center of shaper frame 3052 in order to limit stress due at theconnections.

A mold core assembly 190 is positioned between mold cavity plates 194and defines the mold core when cavity plates 194 are in their closedposition. Mold core assembly 190 substantially does not move in thedirection of the clamping axis C1-C1, but can be moved along aperpendicular core axis C2-C2.

Mold core assembly 190 includes an outer core 7030 and an inner core7052. The outer core 7030 is generally annular in cross-section, and theinner core 7030 is received through the outer core and is movablerelative to outer core 7030 along core axis C2-C2.

A core cap 7034 is positioned atop inner core 7032 and is coupled toinner core 7032 by way of a mounting block 7035. Coupling of inner core7032 to core cap 7034 is achieved using quick-connect couplings 7037(FIGS. 24R-24S). For example, the quick-connect couplings 7037 may becontrolled by a locking device (not shown). With the locking deviceengaged, couplings 7037 retain the core such that it cannot moverelative to core cap 7034. However, the locking device may be disengagedto release the connection of the core to core cap 7034. Movement of corecap 7034 selectively applies or releases a preload force against outercore 7030 and inner core 7032.

As best shown in FIG. 24G, in the depicted embodiment, a locking device7031 includes an actuator, namely a piston 7038 that can be selectivelyextended or retracted (e.g. by electronic or pneumatic control).Extension or retraction of piston 7038 causes extension or retraction ofa locking block 7039. In an extended (locked) position, locking block7039 interlocks with a flange of a retaining device 7041 fixed tomounting block 7035. Interlocking of block 7039 and retaining device7041 prevents movement of core cap 7034, mounting block 7035 andretaining device 7041, relative to locking device 7031.

Inner core 7032 and outer core 7030 mate to a core support block 7042,which is in turn fixedly mounted to shaper frame 3052.

Core cap 7034 is movable by actuators 7046. In the depicted example, twoactuators 7046 are present. However, in other embodiments, more or feweractuators could be used.

In the depicted example, actuators 7046 are roller screws driven byelectric motors. However, other types of linear actuators may be used,such as pneumatic or hydraulic cylinders.

Each actuator 7046 includes a housing 7048 and an output shaft 7050.Housing 7048 is rigidly coupled to a floating support plate 7052. Outputshaft 7050 is coupled to housing 7048 and to a fixed support plate 7054.

Each fixed support plate 7054 is rigidly coupled (e.g., bolted) torespective platen 196. Each floating support plate 7052 is free to moverelative to the corresponding fixed support plate 7054 in bothdirections along core axis C2-C2.

Movement of floating plates 7052 relative to fixed plates 7054 is causedby operation or actuators 7046. Specifically, extension of output shaft7050 pushes housing 7048 and floating plate 7052 away from fixed plate7054 and the platen 196 to which it is mounted. Conversely, retractionof output shaft 7050 pulls floating plate 7052 toward the correspondingfixed plate 7054 and the platen 196 to which it is mounted. One or moreguide rods 7056 may be mounted to each fixed plate 7054 and extendthrough a corresponding slot in floating plate 7052 in order toconstrain movement of floating plate 7052 relative to fixed plate 7054.Specifically, guide rods 7056 are parallel to core axis C2-C2 andconstrain movement of floating plate 7052 to be parallel to that axis.

Because actuators 7046 and fixed plates 7054 are mounted to platens 196,they move along with the platens as clamping assembly 3042′ is openedand closed. Thus, actuators 7046 move relative to core assembly 190 andcore cap 7034 along clamping axis C1-C1.

A lifter 7058 may extend between floating plate 7052 and core cap 7034.Lifter 7058 couples floating plate 7052 and core cap 7034 in thedirection of the core axis. In other words, lifter 7058 and floatingplate 7052 engage one another so that movement of the lifter in eitherdirection along core axis C2-C2 causes movement of core cap 7034 in thesame direction, The connection between lifter 7058 and floating plate7052 is slidable, such that floating plate 7052 can move along clampingaxis C2-C2 while the lifer and the floating plate remain engaged withone another.

As best shown in FIG. 24A, lifter 7058 has a pair of arms 7059 and anextension of floating plate 7052 is received between the arms in avertically interlocking relationship. In other embodiments, lifter 7058may be permanently fixed to floating plate 7052 and project towards corecap 7034. In the depicted embodiment, lifter 7058 is a discretestructure that is coupled to core cap 7034. However, lifter 7058 may beintegrally formed with one of core cap 7034 or floating plate 7052

Movement of floating plate 7052 causes the floating plate to contactlifter 7058, such that core cap 7034 can be forced upwardly ordownwardly. In the depicted example, lifter 7058 contacts floating plate7052 in an interlocking relationship.

Retraction of output shaft 7050 causes floating plate 7052 to movedownwardly toward fixed plate 7054. Lifter 7058 contacts and bearsagainst core cap 7034, forcing core cap 7034 and core cap 7034downwardly against inner core 7032 and outer core 7030.

Extension of output shaft 7050 causes floating plate 7052 to moveupwardly, away from fixed plate 7050. Lifter 7058 contacts and bearsagainst core cap 7034, forcing core cap 7034 and core cap 7034 upwardlyand away from inner core 7032 and outer core 7030.

A guide structure is provided to maintain alignment between floatingplates 7052 and fixed plate 7054. Specifically, guide pins 7060 projectupwardly from each fixed plate 7054 and extend through the correspondingfloating plate 7052. Guide pins 7060 constrain the movement of floatingplate 7052 such that the floating plate can only move along the axis ofthe guide pin.

FIG. 24H depicts mounting of inner core 7032 and outer core 7030 to coresupport block 7042 in greater detail. Core support block 7042 is rigidlymounted such that it does not move during operation of shaper module3054′. For example, core support block 7042 may be mounted to shaperframe 3052 or to fixed platens.

Inner core 7032 and outer core 7030 are received through core supportblock 7042 and supported thereon with a core reset assembly 7070. Duringmolding, core reset assembly 7070 is compressed under a preload forcewith which inner core 7032 and outer core 7030 are urged into the moldcavity to resist molding pressure. At mold opening, core reset assembly7070 urges inner core 7032 and outer core 7030 into neutral positionsfor release of molded parts.

Core reset assembly 7070 includes a retainer ring 7072 and a core loadspring 7074. Retainer ring 7072 cooperates with outer core 7030 and coresupport block 7042 to define a pocket in which core load spring 7074 isreceived. When inner core 7032 and outer core 7030 are urged downwardlyby core cap 7034, retainer ring 7072 bears against load spring 7074 andcompresses it. The downward (closing) force exerted on inner core 7032and outer core 7030 may be referred to as a preload and exceeds theopening force due to pressure within the mold cavity during molding,such that the closing force on inner core 7032 and outer core 7030 issufficient to resist the injection pressure.

When the preload on inner core 7032 and outer core 7030 is released,load spring 7074 rebounds and bears against retainer ring 7072, which inturn bears against a flange 7080 of outer core 7030, moving outer core7030 slightly upwardly. Such movement brings outer core 7030 out ofcontact with mold cavity plates 194, such that the plates 194 may beopened without outer core 7030 and plates 194 rubbing against oneanother.

FIGS. 24I-24L depict an operational sequence of shaper module 3054′.

FIGS. 24I and 24J are isometric and cross-sectional views, respectively,or snapper module 3034 in a mold-open state. Drive links 3074 androckers 3076, 3078 are positioned so that platens 196 (and thus, cavityplates 194) are spaced apart from one another.

As will be apparent, shaper module 3054′ affords relatively unobstructedaccess to the mold area when the mold is open. Specifically, with themold open, operators or machinery may access mold core assembly 190,cavity plates 194 or other components between platens 196 from adirection transverse to clamping axis C1-C1 and transverse to core axisC2-C2. Such access may simplify operations such as removal of moldedparts, maintenance, or mold changes.

As shown in FIGS. 24I-24J, core actuation assembly 3042′ is also in anopen state, with the mold core assembly 190 withdrawn from its moldingposition. Actuators 7046 are extended, so that they urge floating plates7052 away from fixed plates 7054. Floating plates 7052 in turn movelinkages 7058 upwardly, thereby urging core cap 7034 upwardly away frominner core 7032 and outer core 7030.

Core reset assembly 7070 is in an unloaded state, with load spring 7074extended. Extension of load spring 7074 causes retainer ring 7072 tobear against outer core 7030, thereby pushing the core along core axisC2-C2, away from its molding position.

After a completed part is removed, shaper module 3054′ returns to itsmolding configuration for a new molding cycle. FIGS. 24K-24L areisometric and cross-sectional views, respectively, showing shaper module3054′ in an intermediate configuration, with cavity plates 194 andplatens 196 open and mold core 190 approximately in its moldingposition..

Transition of shaper module 3054′ from an open to a closed (molding)state begins with movement of core assembly 190 towards its moldingposition. Specifically, actuators 7046 of core actuation assembly 3042′retract output shafts 7050. Retraction of output shafts 7050 drawsfloating plates 7052 downwardly towards fixed plates 7054. Floatingplates 7052 in turn bear against lifters 7058, urging the lifters andcore cap 7034 downwardly.

As lifter 7058 and core cap 7034 are pulled downwardly, core cap 7034bears against inner core 7032 and outer core 7030. Downward movement ofcore cap 7034 therefore also causes downward movement of inner core 7032and outer core 7030.

The position of core cap 7034 may be measured by an optical sensor, aphysical probe or another suitable sensor. Additionally oralternatively, the position of core cap 7054 may be determined based onthe status of actuators 7046. For example, actuators 7046 may beequipped with encoders to report the position of output shafts 7050.

When core assembly 190 reaches the molding position, shown in FIGS.24K-24L, clamping assembly 3042′ is activated to move platens 196 andcavity plates 194 to their molding positions. Drive links 3074 areextended by drivetrain 7006 and cause rockers 3076, 3078 to urge platens196 towards one another.

Cavity plates 194 contact one another in their molding positions, i.e.,in the closed position of clamping assembly 3042′. In the closedposition, core assembly 190 is enclosed within the cavity defined by thecavity plates.

When cavity plates 194 reach their closed positions, shown in FIGS.24M-24N, core cap 7034 is again urged downwardly by actuators 7046 toapply a preload to core assembly 190. Core cap 7034 is urged againstinner core 7032 and outer core 7030. Outer core 7030 in turn bearsagainst retainer ring 7072 and load spring 7074 of core reset assembly7070. The load spring 7074 is compressed by retainer ring 7072. Acompressive force is exerted against load spring 7074. As load spring7074 compresses, shoulder 7033 of outer core 7030 are pressed intosealing contact with corresponding surfaces of cavity plates 194. Thepreload force is sufficient to resist movement of core assembly 190 dueto pressure from injected molding material, and to prevent leakage ofmolding material at the sealing surfaces. The applied preload force istypically determined using the product of the injection pressure atwhich the mold will be operated and the projected area of the moldcavity. The applied preload force may be measured, for example, using aload cell, or inferred, for example, based on electrical current drawnby actuators 7046.

Drivetrain 7006 exerts closing pressure against platens 196 and cavityplates 194 by way of drive links 3074 and rockers 3076, 3078. The drivepressure exceeds the pressure expected from injection of moldingmaterial into the mold cavity, and maintains the cavity plates 194 intight abutment during molding. As previously noted, application ofclosing pressure against platens 196 results in reaction forces beingtransferred through linkage 3070″″. Such transfer of forces results intension being placed on tie bars 7002 by way of pivotable connections3082.

Molten molding material is injected into the mold cavity defined bycavity plates 194 and core assembly 190. After injection, the moldingmaterial is allowed to cool and harden.

FIGS. 240-24V depict operation of shaper module 3054′ after forming of amolded article.

As shown in FIGS. 240-24P, mold assembly 190 is moved by the moldactuation subassembly 3044′ while clamp subassembly 3042′ is maintainedin its closed position. Actuators 7046 extend output shafts 7050,thereby urging floating plates 7052 away from fixed plates 7054.

As floating plates 7052 are forced upwardly, they push lifters 7058 andcore cap 7034 upwardly. Once core cap 7034 moves slightly upwardly, corereset assembly 7070 is no longer restrained. Accordingly, load spring7074 extends back to its uncompressed condition and urges retainer plate7072 upwardly. Retainer plate 7072 bears against outer core 7030 and maypush the outer core upwardly. Such upward movement brings outer core7030 out of contact with cavity plates 194. Thus, platens 196 and coreplates 194 may be withdrawn without causing damage due to frictionbetween outer core 130 and cavity plates 194.

Once outer core 7030 is lifted out of contact with cavity plates 194,linkage 3070+″, platens 196 and mold cavity plates 194 are moved totheir open positions, shown in FIGS. 24Q-24R.

With the platens 196 and cavity plates 194 in the mold-open position,mold core assembly 190 is moved to its mold-open position, shown inFIGS. 24I-24J, and the molded part is removed. As shown, cavity plates194 are opened with the molded part lightly held on inner core 7032. Thereleased part may be removed from the mold using a handling device. Inother embodiments, the part may be fully dislodged from core assembly190 prior to opening cavity plates 194, such that the part falls outupon opening.

Core cap 7034 pulls inner core 7032 upwardly. Thus, inner core 7032retracts along core axis C2-C2 relative to outer core 7030. Suchrelative movement of inner core 7032 and outer core 7030 dislodges themolded part from core assembly 190.

The molded part tends to have some resistance to removal from the coreassembly. That is, the part tends to stay on the mold inner core 7030.However, when inner core 7032 is pulled upwardly, a top edge of themolded part abuts an annular edge of outer core 7030. The annular edgeof the outer core prevents the molded part from being withdrawn alongwith the inner core and dislodges the part from inner core 7032.

Retraction of inner core 7032 may occur in two stages, namely, aninitial short movement, followed by a longer movement. The initialmovement may be fast, in order to break the molded part loose from innercore 7032. For example, the initial movement may overcome suction thatcan occur between the molded part and inner core 7032. A second, longer,movement of inner core 7032 further withdraws the inner core from themolded part, until the molded part can freely fall or be easily removedfrom the core.

Conveniently, the configuration of shaper station 3054′ providesflexibility for part removal. Because linkage 3070″″, drive train 7006,shaper frame 3052′ and tower structure 7000 are disposed on the sameside of the mold, i.e. on one side of bounding envelope E (FIG. 24A),the opposite lateral side of bounding envelope E is substantiallyunobstructed, as is the bottom. Accordingly, material handling devicesmay freely access the space between platens 196 from the bottom or fromthe unobstructed lateral side to remove parts.

The access afforded by the configuration of shaper module 3054′ alsoeases the process of changing or performing maintenance on moldcomponents.

FIGS. 24S-24T depicts shaper module 3054′ in a configuration for removalof mold cavity plates 194. Clamping assembly 3042′ includes a wedgeblock (not shown), that is operable to selectively lock cavity plates194 in their closed positions. The wedge block may, for example, bemounted to shaper frame 3052′ and may be extended into contact withcavity plates 194 to bias the cavity plates to their closed positions.Some embodiments may include multiple wedge blocks, e.g. one per cavityplate.

As shown in FIG. 24S, with the wedge block engaged, cavity plates 194remain in their closed positions when platens 196 are opened. Couplings(not shown) between cavity plates 194 and platens 196 are configured torelease upon application of force away from the platens, such thatopening of the platens with the wedge block engaged disconnects the moldcavity plates 194 from the platens.

As shown, cavity plates 194 are removed from platens 196 while coreassembly 190 is positioned between the cavity plates. Thus, the mold maybe removed from shaper module 3054′ as an intact unit, i.e. cavityplates 194 may be removed with mold core assembly 190 captive betweenthe cavity plates.

In order to permit removal of core assembly 190, it is detached fromcore cap 7034. Specifically, couplings 7037 are released so thatmounting block 7035 and core cap 7034 can be separated from one another.After the couplings are released, actuators 7046 extend drive shafts7050 to push floating plates 7052, lifters 7058 and core cap 7034upwardly. The maximum extension on drive shafts 7050 is sufficient toraise core cap 7034 clear of mounting block 7035.

Once core cap is clear of mounting block 7035, cavity plates 194 andcore assembly 190 can be removed from shaper module 3054′ as a singleassembly. Conveniently, shaper core 3054′ provides sufficient clearancefor machinery to access and remove the mold assembly from the sideopposite shaper frame 3052′ and linkage 3070″″.

Primary Shaping Mold

With primary reference to FIGS. 25-28, details of example molds for useat a station of shaping cell 104 will now be described. The depictedembodiments are molds for injection molding, such as injection moldingof preforms from which containers may be formed. However, many featuresof the described embodiments are not limited to injection molding, aswill be apparent.

In mold sub-assemblies 3040 and 3040′ as illustrated in FIGS. 12B-D andFIGS. 24A-T respectively, each platen 196 may have secured thereto oneor more services blocks 5196 (see FIGS. 25A and 28A). Attached to eachservices block 5196 may be a cavity plate 194. Cavity plates 194 maytake a wide range of configurations. Cavity plates 194 of differentconfigurations may be interchangeable with one another on a servicesblock 5196 within mold sub-assemblies 3040, 3040′. With particularreference to FIGS.25A to 28B, examples of cavity plates 194 areillustrated and are described hereinafter in detail.

With reference to FIGS. 25A and 28A, services block 5196 may beconnected to a platen 196 by threaded bolts 5197 received throughopenings 5198 in services block 5196 and into threaded openings 5195 ina platen 196.

Services block 5196 may have channels operable for delivering servicessuch as pressurized air, cooling fluid, electrical/electronic servicesto a cavity plate 194. Services block 5196 may during operation ofplastic molding system 100 remain connected to a platen 196.

In some embodiments, cavity plate 194 may be a single unitary body. Inother embodiments, cavity plate 194 may have two separately identifiableportions. The two portions may be integrally formed to create a singlecontinuous unitary body or the two portions may be configured as twoseparate units or parts and be connected to each other during operationof plastic molding system 100.

In the embodiments of FIGS. 25A to 25K, each cavity plate 194 comprisestwo separately identifiable portions: a base portion and a mold cavityportion. The base portion, which is identifiable as a base block 5000,may be first formed as a separate body, and then the mold cavityportion, which is identifiable as a mold cavity block 5010 or 5010′, maybe formed by a manufacturing process by which the two portions/blocksare melded or merged together into a cavity plate 194 that comprises asingle unitary body.

In the embodiments of FIGS. 26A-J, each cavity plate 194 comprises twoseparate parts: a base part (also referred to herein as a base block5000) and a mold cavity part (referred to herein as a mold cavity block5010″ or 5010′″). In these embodiments of FIGS. 26A -J, base block 5000and mold cavity block (5010″ or 5010′″) are formed as separate parts andthen connected together by a connection mechanism.

Each mold cavity block 5010, 5010′, 5010″, 5010′″ of a cavity plate 194may be formed in a specific configuration that is adapted to provide onehalf of an outer mold cavity surface for an item to be molded having aparticularly desired profile/shape. In a plastic molding system 100, aplurality of differently configured cavity plates 194, with differentlyconfigured mold cavity blocks 5010, 5010′, 5010″, 5010′″ withdifferently configured mold cavity surfaces, may be available forselection and use in a mold sub-assembly 3040, 3040′.

In the embodiments of FIGS. 26A-J, each base block 5000 may beconfigured and operable to connect to, and disconnect from, a pluralityof differently configured mold cavity blocks 5010″, 5010′″ which whenused in a pair of mated mold cavity blocks 5010″ or 5010′″ may provide adifferently shaped molding cavity surface to produce a differentlyshaped/configured molded item.

Each base block 5000 of a cavity plate 194 may have one or more “quickconnection” mechanisms (as described further hereinafter) for couplingeach cavity plate 194 to a services block 5196 and thus to a platen 196.

With reference again to the embodiment of cavity plate 194 depicted inFIGS. 25C-D, further details of base block 5000 and mold cavity blocks5010, 5010′ of a cavity block 194 are illustrated in FIGS. 25E-K andFIGS. 27A-B, as described hereinafter.

With particular reference to FIG. 27B, base block 5000 may be used withany of mold cavity blocks mold cavity blocks 5010, 5010′, 5010″, 5010′″to form a cavity plate 194. Base block 5000 may have a length Y1 andwidth X1.

With reference to FIG. 25G, mold cavity block 5010′ may have a length Y2and width X2. X1 may be the same magnitude as X2, and Y1 may be the samemagnitude as Y2. Mold cavity blocks 5000, (as well as mold cavity blocks5000″ and 5000′″) may have the same length and width Y2 and X2.

With reference to FIGS. 27A and 27B, each base block 5000 may have amold cavity block facing surface 5000 a (FIGS. 27A) that may begenerally planar and extend vertically (direction Y) and transversely(direction X). Mold cavity block 5010, 5010′ of FIGS. 25A to 25K may beformed by an additive manufacturing process whereby by deposition of amaterial on top of mold cavity block facing surface 5000 a the materialbonds to the material of base block 5000 at mold cavity block facingsurface 500 b of base block 5000.

In other embodiments, mold cavity block 5010″ (FIG. 26B), may have abase block facing surface 5010′a that may be generally planar and extendvertically (direction Y) and transversely (direction X). Base blockfacing surface 5010 a″ of mold cavity block 5010 and mold cavity blockfacing surface 5000 a of base block 5000 may be configured to be able toconnected together and be held in face to face, flush mating contactwith each other. Base block 5000 may also have, on the opposite side tomold cavity block facing surface 5000 a, a services block facing surface5000 b (FIG. 27B) that may also be generally planar and extendtransversely. Services block facing surface 5000 b of base block 5000 ofcavity plate 194 may be operable to be able to be connected and be heldin face to face flush mating contact with a generally planar andtransversely extending surface 5196 a of a services block 5196associated with a platen 196 (FIGS. 25A, 25C, 25D, 26A, 26B, and 28A).

The connection mechanism employed between the base block 5000 of acavity plate 194 and the mold cavity block 5010″, to hold surfaces 5000a and 5010 a″ in face to face, flush mating contact and in engagementmay be, or may not be, a mechanism that provides for a relatively easyand quick connection to, and disconnection from, each other. Each baseblock 5000 may be disconnected from, and connected to, a mold cavityblock 5010″ when the cavity plate 194 is removed from moldsub-assemblies 3040 and 3040′. It is contemplated in the embodiments ofFIGS. 26A -J each base block 5000 may be connected to and disconnectedfrom, a mold cavity block 5010″, 5010′″ using threaded bolts 5025received through open holes 5026 that pass through base plates 5000 andextend longitudinally (direction Z) into threaded holes (not shown)appropriately positioned in cavity block 5010″ (see FIGS. 26D and 26G).

With reference again to FIGS. 27A and 27B, counter-bore openings 5003may be provided when extend longitudinally through the body of each baseblock 5000. Openings 5003 are adapted to receive therein and securethreaded base portions of alignment dowels (5004 (FIG. 25B) which mayhave portions that pass through openings in the mold cavity block 5010′to which the base block 5000 is attached (in the embodiments of FIGS.26A-J) and extend longitudinally outwards. A protruding end of analignment dowell/pin may be received in a corresponding opening in themold cavity block (as for example as described further below).

Additionally, each base block 5000 may have upper clamp connectionopenings 5002 a, 5002 b on upper horizontal surface 5000 c and lowerclamp connections have lower clamp connection openings 5002 c, 5002 d onlower horizontal surface 5000 d (FIGS. 27A, 27B). These clamp connectionopenings may be utilized to connect to fixtures during manufacturing ofthe base blocks 5000 themselves (eg. when clamping of base blocks 5000is required) or when combining the base block with a mold cavity block5010, 5010′, 5010″ or 5010′″. Such clamp connecting openings may also beused to connect to fixtures associated with a handling robot when it isrequired to conduct tooling maintenance activities. Additionally, lowerclamp connection openings 5002 c, 5002 d may also be used for retaininggate cutter assembly 2200 as referenced above.

Another connection mechanism is employed between base block 5000 andservices block 5196 to releasably but securely hold surfaces 5000 b and5196 a in face to face, flush contact and engagement. Thisconnection/retaining mechanism may be a quick connection/disconnectionmechanism (referred to herein as a “quick connection” or “quick connect”mechanism) that facilitates relatively easy and quick connection anddisconnection of each base block 5000 of a cavity plate 194. A “quickconnection” or “quick connect” mechanism may be considered herein to bea mechanism whereby the connection and disconnection between the twocomponents can be affected relatively easily and it has one or more ofthe following functional characteristics.

One characteristic indicative of a quick connection is that theconnection and disconnection mechanism is selectively engageable to holdthe base block 5000 against the services block 5196.

Another characteristic indicative of a quick connection is that themechanism has the capability of selectively interlocking the base block5000 and the services block 5196.

Another characteristic indicative of a quick connection is that themechanism is operable to provide a clamping action when connecting baseblock 5000 and the services block 5196.

Another characteristic indicative of a quick connection is that themechanism is switchable between connected and disconnected states toconnect and disconnect the base block 5000 and the services block 5196.

Another characteristic indicative of a quick connection is that theconnection and/or disconnection is made by way of a spring activatedforce operating between a part on the base block 5000 and the servicesblock 5196.

Another characteristic indicative of a quick connection is that theconnection and/or disconnection does not require the installation offasteners eg. does not involve twisting or turning forces to be appliedto screws, bolts, nuts, or the like.

By way of example, a quick connect mechanism like retaining mechanism4014 illustrated in FIG. 4H as described above may be employed toreleasably connect a base block 5000 to a services block 5196. Aconnection/retaining mechanism such as the model 306019 zero pointpull-stud and model 305979 zero point clamping module socket availablefrom AMF (Andreas Maier GmbH & Co KG referred to herein as “AMF”—seewww.amf.de/en) . Thus, the connection/retaining mechanism may include aplurality of vertically spaced studs 4024 and a corresponding pluralityof mating sockets 4026 which can selectively interlock with the studs.The studs 4024 (FIGS. 25B, 27B) may be mounted on and extendlongitudinally (direction Z) outward from services block facing surface5000 b of base block 5000 of cavity plate 194 and engage with a socket4026 formed in base block facing surface 5196 a of services block 5196(FIG. 25A) and which extends longitudinally (direction Z) into the bodyof services block 5196 (see also FIG. 28A).

Other features of this retaining mechanism shown in FIG. 4H aredescribed above. By providing a quick connect mechanism wherebydifferent molding cavity plates 194 can be readily interchanged on aservices block 5196, the mold sub-assemblies 3040, 3040′ can be easilyand quickly changed from one particular set-up to another set-up withoutsignificant changeover downtime.

Each base block 5000 and services block 5196 may each be made from anysuitably strong and rigid material or combination of materials, such asfor example 1.2085 grade steel or AISI 422 stainless steel.

A suitably sized, generally cuboid shaped block may be initially formedsuch as by casting using known techniques and methods, and then theparticular features of the base block 5000 and services block 5916 asdescribed herein may be formed in the cast block using knownmanufacturing techniques and methods such as conventional machiningapparatuses and methods.

Each mold cavity block 5010, 5010′, 5010″, 5010″″ may also be made fromsuitably strong and rigid material(s) such as for example 1.2085 or AISI422 steel.

In the embodiments of FIGS. 26A-J, a suitably sized, generally cuboidshaped block may be initially formed such as by casting using knowntechniques and methods, and then the particular features of the moldcavity block 5010″, 5010′″ as described herein may be formed in the castblock using known manufacturing techniques and methods such asconventional machining apparatuses and methods.

One technique that may be employed for forming a mold cavity block 5010,5010′, including forming the shape of its mold cavity wall surface 5011,5011′ and interior core alignment surface 5009, 5009′ (FIG. 25D-K) is a3D printing process, and in particular direct metal laser sintering(DMLS). Such a process can be employed in which the material is directlyapplied and deposited on top of surface 5000 a of a base block 5000 suchthat the 3D profile of the mold cavity block 5010, 5010′ is built on topof the base block. Such a process has flexibility in terms of the shapeof the mold cavity wall surface 5011, 5011′ that can be formed andallowing the formation of internal hollow features, such as providinghollow service channels therein (eg. fluid cooling channels). Such anadditive manufacturing process provides a high level of flexibility inbeing able to provide an optimized cooling fluid channel which cansurround/cover the entire molding cavity surface. Traditionalmanufacturing techniques may not be able to achieve the sameconfiguration/placement of cooling channels or if they can, it may bevery difficult to achieve and incur extremely high cost.

With particular reference now to FIGS. 27A -B and FIG. 28B, base block5000 may be provided with one or more service channels extending therethrough. Such services may include pressurized air (which can be used tooperate a quick connection mechanism operating between a base block 5000and a services block 5196), electrical/electronic wiring (eg. forelectronically/electronically connecting to sensors such as temperaturesensors), and fluid cooling (eg. cooled gas; cooled water) channels.

By way of example, in the embodiment of FIGS. 26A-J, where each baseblock 5000 is configured and operable to connect to, and disconnectfrom, a plurality or differently configured mold cavity blocks 5010″,5010′″, base block 5000 may have a fluid cooling channel 5020 (FIG. 28B)that is a part of a cooling fluid circuit 5200 that delivers coolingfluid from a cooling fluid reservoir 5199 to a services block 5196, theninto the base block 5000 and then into a mold cavity block 5010″ (ormold cavity block 5010′″) so as to promote rapid cooling andsolidification of melted material after injection into a mold cavityformed by a pair of mated, clamped mold cavity blocks 5010 (or moldcavity blocks 5010′, 5010″, 5010′″). The cooling fluid circuit 5200returns the cooling fluid to a fluid channel 5181 in the services block5196 for return to the cooling fluid reservoir 5199. Examples of coolingfluid are chilled water, liquid CO₂ and other fluids with different heatexchange characteristics.

Services block 5196 may have a cooling channel 5080 with an output port5050 a. Cooling channel 5020 in base block 5000 may have an input port5020 d in surface 5000 b of base block 5000 which is in fluidcommunication with an aligned output port 5050 a in surface 5196 a ofservices block 5196, when the base block 5000 is engaged with theservices block 5196 as shown in FIGS. 26A and 26B. Fluid channel 5020passes through base block 5000 to an output port 5020 a in surface 5000a of base block 5000 which is in fluid communication with an alignedinput port 5030 a in surface 5010 a of mold cavity block 5010 (FIG. 25B)(or the corresponding surface of mold cavity block 5010′, 5010″,5010′″). Input port 5030 a provides an intake for a cooling channel 5030(FIG. 28B) that that passes through the body of the mold cavity block5010 (or mold cavity block 5010′, 5010″, 5010′″). Cooling channel 5030may be formed to allow cooling fluid to flow along a tortuous paththrough the body of mold cavity block 5010 (or mold cavity block 5010′,5010″, 5010′″) to an output port 5030 b. The tortuous path have portionsthat are configured to conform at least in part to the mold cavity wallsurface to enhance the cooling effect of the cooling fluid within themold cavity block 5010. In some example embodiments, the cooling channel5030 may, at least in part, be formed as an indented groove that may bemilled into base block facing surface 5010 a″ of mold cavity block5010″. The groove may be fully enclosed at its top by the opposed matingsurface 5000 a of base block 5000 when mold cavity block 5010″ isengaged with a base block 5000 and surface 5000 a in mating contact withsurface 5010 a″.

Output port 5030 b in surface 5010 a of mold cavity block 5010 (orcorresponding surface of mold cavity block 5010′, 5010″, 5010′″) is influid communication with an aligned input port 5020 b in surface 5000 bof base block 5000 (FIG. 27A). A second fluid channel 5021 passesthrough base block 5000 from input port 5020 b to an output port 5020 c.The output port 5020 c is in fluid communication with an input port 5050b in services block surface 5196 a of services block 5196.

Services block 5196 has a services channel 5081that providescommunication between input port 5050 b and is in fluid communicationwith cooling fluid reservoir 5199 so that cooling fluid can be returnedto the reservoir.

With reference to the cooling fluid circuit 5200 depicted in FIG. 28B,cooling fluid may be communicated from the cooling fluid reservoir 5199by various cooling fluid channels passing through other components ofthe mold sub-assembly 3040, 3040′ into the cooling channel 5080 in theservices block 5196, then pass into the cooling channel 5020 in baseblock 5000 and then into the cooling channel 5030 in mold cavity block5010″ (or mold cavity block 5010″'). Cooling fluid may then flow throughthe cooling channel 5030 and exit output port 5030 b into input port5020 b into the cooling channel 5021 in base block 5000 where it canflow through channel 5021 exiting into input port 5050 b in servicesblock surface 5196 a of the services block 5196. Then the cooling fluidcan flow through cooling fluid channel 5181 to be returned to thecooling fluid reservoir 5199 by various channels passing through othercomponents of the mold sub-assembly 3040, 3040′. As part of the coolingfluid circuit 5200, in addition to the cooling fluid reservoir 5199 andthe flow channels, an apparatus for cooling the fluid is required aswell as a pump and possibly valves to provide for a cooling fluid flowto and from the mold cavity blocks 5010.

Each of cooling fluid input port/output port couplings 5020 a/5030 a;5030 b/5020 b; and 5020 c/5050 b may be any suitable cooling fluidcommunication fittings. For example, suitable water fittings forcouplings 5020 c/5050 b may be the model AMF 6989N [164988, built-incoupling nipple] and 6989M [164996, built-in coupler] water fittingsmade by AME Couplings 5030 a/5020 a; and 5030 b/5020 b may be suitablesealing O-rings between the mated surfaces of base block 5000 and moldcavity block 5010″ (or mold cavity block 5010′″) of cavity plate 194 andin particular in the vicinity of where channels 5020 and 5021 connectwith channel 5030.

In such water fittings, there may be provided a valve mechanism thatopens and closes the channel of fluid flow. When the male part of such acooling fluid fitting is received into the female part, the valvemechanism is opened. When the male part is removed from the female part,the valve mechanism is closed. The valve mechanism may be provided onthe cooling fluid source side of the fluid circuit supply arrangement,such as for example, at the output port 5050 a on a services block 5196.Accordingly, when a base block 5000 is removed from connection toservices block 5196, cooling fluid will not flow out of output port 5050a on the services block 5196.

It is also noted that with male/female type couplings (both coolingfluid fittings and fittings associated with the connection/retainingmechanism referenced above) between the base blocks 5000 and theservices blocks 5196, there will be a male part and a female part. Insome embodiments, the female part of the couplings may be formed in theservices block 5196 and the male part of the coupling on the base block5000. This is because the male part of such a coupling is typically aless expensive component and in any molding system 100, there may be amuch greater number of base blocks 5000 that are utilized compared tothe number of service blocks 5196, it may be cost effective to providethe male parts of such cooling fluid fittings and retention/connectionmechanisms, on the base blocks 5000. In other embodiments, the male partof the couplings may be formed in the services block 5196 and the femalepart of the coupling on the base block 5000.

Similarly, in the embodiments of FIGS. 25A-25K, where each base block5000 is integrally connected with a mold cavity block 5010 (or a moldcavity block 5010′). Again each base block 5000 may have a fluid coolingchannel 5020′ (FIG. 28C) that is a part of a cooling fluid circuit 5200′that delivers cooling fluid from a cooling fluid reservoir 5199 to aservices block 5196, into the base block 5000 and then into a moldcavity block 5010 (or mold cavity block 5010′) so as to promote rapidcooling and solidification of melted material after injection into amold cavity formed by a pair of mated, clamped mold cavity blocks 5010(or mold cavity block 5010′). The cooling fluid 5200′ returns thecooling fluid to a fluid channel 5181′ in the services block 5196 into afluid channel in platen 196 for return to the cooling fluid reservoir5199.

Services block 5196 may have a cooling channel 5080′ with an input port5051 a and an output port 5050 a. Cooling channel 5020′ in base block5000 may have an input port 5020 d in surface 5000 b of base block 5000which is in fluid communication with an aligned output port 5040 a insurface 5196 a of services block 5196, when the base block 5000 isengaged with the services block 5196 as shown in FIGS. 26A and 26B.Fluid channel 5020′ passes through and is integrally connected for fluidcommunication with a cooling channel 5030′ (FIG. 28C) that that passesthrough the body of the mold cavity block 5010 (or mold cavity block5010′). Like cooling channel 5030, cooling channel 5030′ may be formedto allow cooling fluid to flow along a tortuous path through the body ofmold cavity block 5010 (or mold cavity block 5010′) and then fluidlyconnect with a second fluid channel 5021′ passes through base block 5000to an output port 5020 c. Output port 5020 c is in fluid communicationwith an input port 5050 b in services block surface 5196 a of servicesblock 5196.

Services block 5196 has a services channel 5081′ that providescommunication between input port 5050 b and output port 5051 b. Outputport 5051 b is in communication with an input port 5040 b in platen 196.

With reference to the cooling fluid circuit 5200′ depicted in FIG. 28C,cooling fluid may be communicated from the cooling fluid reservoir 5199by various cooling fluid channels passing through other components ofthe mold sub-assembly 3040, 3040′ into the platen 196 and then exit froman output port 5040 a at platen surface 196 a of platen 196, and passinto and through the cooling channel 5080 in the services block 5196,then pass into the cooling channel 5020′ in base block 5000 and theninto the cooling channel 5030′ in mold cavity block 5010 (or mold cavityblock 5010′). Cooling fluid may then flow through the cooling channel5030′ and then flow through channel 5021′ exiting into input port 5050 bin services block surface 5196 a of the services block 5196. Coolingfluid can then flow through cooling fluid channel 5181′ to an input port5040 b in platen surface 196 a of the platen 196 to which service block5196 is mounted. Cooling fluid may then flow through the platen 196 andbe returned to the cooling fluid reservoir 5199 by various channelspassing through other components of the mold sub-assembly 3040, 3040′.As part of the cooling fluid circuit 5200′, in addition to the coolingfluid reservoir 5199 and the flow channels, an apparatus for cooling thefluid is required as well as a pump and possibly valves to provide for acooling fluid flow to and from the mold cavity blocks 5010.

Each of cooling fluid input port/output port couplings 5051 a/5040 a;5050 a/5020 d; 5020 c/5050 b and 5051 b/5040 b may be any suitablecooling fluid communication fittings. For example, suitable waterfittings for couplings 5051 a/5040 a; 5050 a/5020 d; 5020 c/5050 b and5051 b/5040 b may also be the model AMF 6989N [164988, built-in couplingnipple] and 6989M [164996, built-in coupler] water fittings made by AMF.

In addition to base block facing surface 5010 a, in the embodiments ofFIGS. 25G-H, mold cavity blocks 5010 have an upper horizontal surface5010 c and a lower horizontal surface 5010 d, which are generallyparallel to each other and orthogonal to surface 5010 a. On the oppositeside of base block 5000 to base block facing surface 5010 a, may be acavity side 5010 b with a surface topography generally designated 5012,which may vary in its configuration depending upon one or more ofseveral factors including the configuration of the item which is desiredto be molded between a pair of mated mold cavity blocks 5010 and thetype of molding material that is going to be injected into the cavity.Cavity side surface topography 5012 typically includes at least asurface area for forming half of a mold cavity and a contact surfacearea that is configured to engage an opposite contact surface on acorresponding mating mold cavity block. In mold cavity block 5010, acontact surface area 5010 g may be provided that is generally parallelto base block facing surface 5010 a. Extending interiorly of contactsurface area 5010 g is a cavity wall surface 5011 which defines theouter surface of a cavity half 5015. The orientation of cavity wallsurface 5011 is such that the lengthwise axis of the cavity wall surface(in the Y direction) that leads to the top open end of the mold cavityis vertical such that the split line is a longitudinal line on eitherside of the item to be molded. In other words, the cavity wall surface5011 provides a longitudinal sectional surface profile of the item to bemolded with the item to be molded having an opening at a vertical end ofthe profile.

Mold cavity block 5010′ is similar in configuration as shown in FIGS.25I-K. in which a contact surface area 5010 g′ may be provided that isgenerally parallel to base block facing surface 5010 a′. Extendinginteriorly of contact surface area 5010 g′ is a cavity wall surface5011′ which defines the outer surface of a cavity half.

In each mold cavity block 5010, 5010′, located above cavity wall surface5011, 5011′ is a core alignment surface area 5009, 5009′ which ingenerally tapered inwardly towards the cavity wall surface 5011, 5011″,and which defines half of the cavity adapted to receive and align theouter core 7030 and an upper part of the inner core 7032 of a mold coreassembly 190 (see FIGS. 25D, 25E) that is received within the cavityformed by cavity wall surfaces 5011, 5011′.

During operation of system 100, the inner core 7032 extends verticallyinto the mold cavity formed by opposed cavity wall surfaces 5011, 5011′of opposed mating mold cavity blocks 5010, 5010′ and the wall surface ofinner core 7032.

A gate area 5016, 5016′ may be formed vertically through a lower portionthe body of each mold block cavity 5010, 5010′ to provide a channel fromthe exterior of the mold cavity block into the cavity half 5015 and intothe mold cavity formed when the inner core 7032 and outer core 7030 ofthe mold core assembly 190 are received into cavities formed by interiorcore receiving surfaces 5009, 5009′ and cavity wall surfaces 5011, 5011′of mated mold cavity blocks 5010 (or mated mold cavity blocks 5011′). Itis to be noted that the two opposed, face-to-face gate areas 5016, 5016′of opposed pairs of mold cavity blocks 5010, 5010′ cooperate to define agate structure 5017, 5017′ (FIG. 25D) when, in operation of a moldsub-assembly 3040, 3040′, a pair of mold cavity blocks 5010 (or pair ofmold cavity blocks 5010′) are mated with each other. It is through theformed gate structure 5017′ (FIG. 25D) that molding material may beinjected into the formed mold cavity as generally described herein.

A vent area 5037, 5037′ may also be formed through sides of the body ofeach mold block cavity 5010, 5010′ to provide opposed vent channelsbetween the exterior or the mold cavity block and the interior of thecavity half 5015, 5015′. It will be appreciated that when duringoperation of system 100, two mold cavity blocks 5010 (or mold cavityblocks 5010′) are oriented in face-to-face mated relation with eachother, with opposed contact surface areas 5010 g, 5010 g′ being incontact with, and forced towards, each other, a pair of complete opposedvent structures 5038′ (FIG. 25C) will be formed by the two opposed, faceto face vent areas 5037′ of the opposed mold cavity blocks 5010′. It isthrough the formed vent structures 5038′ (FIG. 25C) that air may escapefrom the interior of the mold cavity as molding material is injectedinto the formed mold cavity.

It will be appreciated that when during operation of system 100, twomold cavity blocks 5010 are oriented in face to face mated relation witheach other, with opposed contact surface areas 5010 g being in contactwith and forced towards each other, the outer surface of a complete moldcavity will be formed by the opposed cavity wall surfaces 5111. Thiswill result in a longitudinal split line being present between the twomating mold cavity blocks 5010 at the inward edges defined by theboundary between cavity wall surfaces 5011 and contact surface areas5010 g. It is important that the mating edges of the two cavity wallsurfaces be in tight, unbroken contact with each other and that theedges be flush with each other to avoid a discontinuity at the join ofthe adjacent cavity mold surfaces. To minimize problems associated witha visible longitudinal split line, it is important that the interfacebetween a pair of mated and engaged mold cavity blocks 5010 becontrolled with a very high degree of tolerance during operation ofsystem 100.

Again with primary reference to FIGS. 25G and 251, in some embodiments,extending from opposed sloped side surfaces 5010 e and 5010 f of moldcavity blocks 5010 may be generally wedge shaped abutments 5033.Abutments 5033 on a stationary mold cavity block 5010 may havelongitudinally extending guide pin openings 5035 to receive a guide pin(not shown in FIG. 25G, but refer to FIG. 26D for similar guide pins5007″) that may be mounted on an opposed wedge shaped abutment 5033 on amoving mold cavity mold block 5010. For further clarity, it may beappreciated that of a pair of mating mold cavity blocks 5010, one moldcavity block 5010 may be stationary during operation of a moldsub-assembly, as it may be secured to a base block 5000 that is mountedto a stationary platen 196, whereas the opposite mold cavity block 5010may move during operation, as it is secured to a base block 5000 that ismounted to a moving platen 196. In other embodiments, both mold cavityblocks 5010 may move during operation a mold sub-assembly, as each moldcavity block 5010 is secured to a base block 5000 that is mounted to amoving platen 196.

Guide pin openings 5035 and guide pins may be formed to very hightolerances to ensure mat when two mold cavity blocks 5010 are broughttogether in face to face mated relation with each other, with opposedcontact surface areas 5010 g being in contact with each other, andforced towards each other, all the features of the desired outersurfaces of the mold cavity are formed properly (eg. the two mold cavityhalves are accurately aligned with each other to assist inavoiding/minimizing visible longitudinal split lines on the moldeditems).

The upper surfaces 5033 a of abutments 5033 are recessed below the levelof contact surface areas 5010 g. Accordingly, when during operation ofsystem 100, two mold cavity blocks 5010 are oriented in face to facemated relation with each other, with opposed contact surface areas 5010g being in contact with and being forced towards each other at aspecific known clamping force, the only surfaces that in contact witheach other will be contact surface areas 5010 g. Thus, the contactpressure at surfaces 5010 g can be calculated as the clamping forcedivided by the area of a contact surface area 5010. Additionally, thecontact pressure desired to ensure proper sealed formation of a moldcavity by two mold cavity blocks may be within a known range. It ispossible that for a particular standard clamp tonnage that is applied bythe clamping mechanism of a mold sub-assembly 3040′, 3040′, theacceptable range of contact surface area can be calculated and providedfor a particular cavity mold block 5010. Thus instead of changing theclamp pressure for differently sized/shaped items to be molded, thesurface contact area 5010 g for a mold cavity block can be selected andthe contact pressure on the surface contact areas 5010 g may beappropriately maintained within a desired range.

An alternately configured mold cavity block 5010′ is shown in FIG.25I-K. Mold cavity block 5010′ may generally configured the same as moldcavity block 5010 including having the same corresponding overall widthX2 but different length Y3, a cooling channel 5030′, and wedge shapedabutments 5033′ with recessed top surfaces 5033 a′. Abutments 5033′ on astationary mold cavity block 5010′ may also have guide pin openings5035′ to receive a guide pin (not shown) that may be mounted on a matedopposed cavity mold block 5010′. However, the configuration of sidesurfaces 5010 e′ and 5010 f′ and cavity wall surface 5011′ may be suchthat a larger contact surface area 5010 g′ is present in mold cavityblock 5010′ compared to the size of the contact surface area 5010 g inmold cavity block 5010.

A mold cavity block 5010′ having the same length Y2 as, or a shorterlength Y3 than, the length Y2 of mold cavity block Y2 of mold cavityblock 5010, for a standard clamping pressure, may require a differentconfiguration of contact surface area 5010 g′ compared to contactsurface area 5010 g to ensure that the contact pressure is within anacceptable range.

Table 1 below, provides an example of how the configuration and size orcontact surface areas can be selected/varied for a variety of differentitems to be molded, where a standard clamping load is applied to clamptogether two opposed cavity mold blocks, and illustrates the resultingcontact pressures from a variety of somewhat differently sized andshaped contact surface areas 5010 g, with a clamping force of 30 tonnes(294 300 N).

TABLE 1 Contact Surface 6000 mm{circumflex over ( )}2 Contact Pressure49.1 N/mm{circumflex over ( )}2 Contact Surface 5750 mm{circumflex over( )}2 Contact Pressure 51.2 N/mm{circumflex over ( )}2 Contact Surface5500 mm{circumflex over ( )}2 Contact Pressure 53.5 N/mm{circumflex over( )}2 Contact Surface 5250 mm{circumflex over ( )}2 Contact Pressure56.1 N/mm{circumflex over ( )}2 Contact Surface 5000 mm{circumflex over( )}2 Contact Pressure 58.9 N/mm{circumflex over ( )}2

Therefore, if the size and shape of the mold cavity surface is differentbetween mold cavity blocks, the shape of the contact surface area can bealtered to some extent between the two mold cavity blocks, to ensurethat with a given set clamping pressure, the contact pressure is heldwithin a desired pressure range.

The ability to vary the shape of the surface contact areas 5010 g, 5010g′, 5010 g″also permits the pressure distributions applied across thecontact surfaces on the mold cavity blocks to be adjusted having regardto the locations of the forces applied via the clamping mechanisms. Insome situations the forces applied by the clamping mechanisms will notbe evenly distributed. The size of the contact surfaces in a particulararea can be adjusted to accommodate uneven application of force by theclamping mechanism, such that the pressure across the entire contactsurface area is fairly even.

A further alternate embodiment of a mold cavity plate 194″ is shown inFIGS. 26D-F which may be formed as two separate parts: (a) a base block5000″; and (b) a mold cavity block 5010″ that may be connected togetherin use. Base block 5000″ may be generally formed like base block 5000including base block 5000″ having side surfaces 5000 e″ and 5000 f″which are generally longitudinally extending and planar. Mold cavityblock 5010″ may be generally formed like mold cavity block 5010 exceptthat its side surfaces 5010 e″ and 5010 f″ are also generally extendingvertically and longitudinally and are planar. As is evident in FIGS.26B, and FIGS. 26D-F, when a mold cavity block 5010″ is mounted to abase block 5000, surface 5010 e″ is generally flush with, and extends insame plane as, surface 5000 e. Similarly, surface 5010 f″ is generallyflush with and extends in the same plane as surface 5000 f.Additionally, surface 5010 c″ is generally flush with and extends in thesame plane as surface 5000 c, and surface 5010 d″ is generally flushwith and extends in the same plane as surface 5000 d. Also, the cavityside surface topography 5012″ of mold cavity block 5010″ can begenerally be devided into areas: (i) a contact surface area 5010 g″ ;(ii) a slightly lower recessed non-contact surface area 5010 h″; and(iii) a cavity wall surface area 5011″. It may be appreciated, that ifthe size and shape of the mold cavity surface is different between twomold cavity blocks 5010″, the shape of the contact surface area 5010 g″and non-contact surface area 5010 h″ can be altered to some extentbetween the two mold cavity blocks, to ensure that with a given setclamping pressure, the contact pressure is held within a desiredpressure range, even though the two mold cavity blocks 5010″ are usedfor producing differently sized/shaped items.

With particular reference to FIG. 26A-C, the mold cavity for an item tobe molded is formed between the outer surface of inner core 7032 and thecavity wall surfaces 5011″ of mated and engaged cavity mold blocks5010″. The upper portion of the mold cavity is sealed by the bottomhorizontal circular ring shaped edge 7030 a of the outer core 7030. Bythe alignment of the outer core 7030 and the upper part of inner core7032 with cavity wall surface 5011′, the lower part of the inner core7032 will be properly positioned within the cavity wall surfaces 5011′to form the precise mold cavity configuration that is desired. Each moldcavity block 5010′ may also have opposed outer side surfaces 5010 e″ and5010 f″.

Again with primary reference to FIGS.26E-F, longitudinally extendingguide pin openings 5035″ may be provided in non-contact surface areas5010 h″ of stationary mold cavity blocks 5010″ (FIG. 26E) interconnectedto a stationary platen 196, to receive a guide pin 5007″ that may bemounted in openings 5008″ on a moving mold cavity mold block 5010″ (FIG.26F) interconnected to a moving platen 196. Guide pin openings 5035″,5008″ and guide pins 5007″ may be formed to very high tolerances toensure that when two mold cavity blocks 5010″ are brought together inface to face mating relation with each other, with opposed contactsurface areas 5010 g″ being in contact with and forced towards eachother, all the features of the desired outer surfaces of the mold cavityare formed properly (eg. the two mold cavity halves are accuratelyaligned with each other to assist in avoiding/minimizing visiblelongitudinal split lines on the molded items).

Additionally, as shown in FIGS. 26D-F, mounting blocks 5060 may besecured by bolts 5063 received in openings 5064 through mounting blocks5060 into aligned threaded openings in surface 5000 b″. Mounting blocks5060 may also be secured to service plates 5196, 5196′ with bolts 5062received through openings 5061 into aligned threaded openings in 5196,5196′. Mounting blocks 5060 help to stabilize the base blocks 5000 (andthe mold cavity blocks mounted thereto), before and when they aresubjected to loading by the clamping mechanism. Advantages of the cavityplate combination of a base block 5000 and a mold cavity block 5010″ isthat the outer surface area is generally consistent or of a standardshape, yet the cavity s surface topography 5012″ can be varied toaccommodate any shape and size (within certain limits) of item to bemolded. Thus, the relative size of contact surface area 5010 g″; lowerrecessed non-contact surface area 5010 h″; can be adjusted and can takeinto account the configuration and size of the cavity wall surface area5011″.

With reference to FIGS. 26A-F, a gate area 5016″ may be formedvertically through a lower portion of the body of each mold block cavity5010″, to provide a channel from the exterior of the mold cavity blockinto the cavity half 5015″ and into the mold cavity formed when theinner core 7032 and outer core 7030 of the mold core assembly 190 arereceived into cavities formed by interior core receiving surfaces 5009″and cavity wall surfaces 5011″ of mated mold cavity blocks 5010″ (FIG.26A). The two opposed, face to face gate areas 5016″ of opposed pairs ofmold cavity blocks 5010″ cooperate to define a gate structure 5017″(FIG. 26D) when, in operation of a mold sub-assembly 3040, 3040′, a pairof mold cavity blocks 5010″ are mated with each other. It is through theformed gate structure 5017″that molding material may be injected intothe formed mold cavity as generally described herein.

Pairs of opposed vent areas 5037″ may also be formed through eachopposed sides of the body of each mold block cavity 5010″ (FIG. 26E) toprovide opposed pairs of vent channels between the exterior of the moldcavity block and the interior of the cavity half 5015″. It will beappreciated that when during operation of system 100, two mold cavityblocks 5010″ are oriented in face to face mated relation with eachother, with opposed contact surface areas 5010 g″ being in contact witheach other and forced towards each other, a pair of complete opposedvent structures will be formed by the two opposed, face to face ventareas 5037′ of the opposed mold cavity blocks 5010′. It is through theformed vent structures that air may escape from the interior of the moldcavity as molding material is injected into the formed mold cavity.

It will be appreciated that when during operation of system 100, twomold cavity blocks 5010″ are oriented in face to face mated relationwith each other, with opposed contact surface areas 5010 g″ being incontact with and forced towards each other, the outer surface of acomplete mold cavity will be formed by the opposed cavity wall surfaces5111″. This will result in a longitudinal split line being presentbetween the two mating mold cavity blocks 5010″ at the inward edgesdefined by the boundary between cavity wall surfaces 5011″ and contactsurface areas 5010 g. Again, it is important that the mating edges ofthe two cavity wall surfaces be in tight, unbroken contact with eachother and that the edges be flush with each other to avoid adiscontinuity at the join of the adjacent cavity mold surfaces. Tominimize problems associated with a visible longitudinal split line, itis important that the interface between a pair of mated and engaged moldcavity blocks 5010″ be controlled with a very high degree or toleranceduring operation of system 100.

With reference now to FIG. 26J, a further mold cavity block 5010′″ isillustrated and in which the cavity side surface topography 5012′″ maybe formed generally in the same manner as the cavity side surfacetopography of mold cavity block 5010″ as referenced above. Base blockfacing surface 5010 a′″ of mold cavity block 5010′ and its surfacetopography and features may be generally be the same manner as that ofmold cavity block 5010″ except for the following. A generally cuboidbottom open trough area 5013′″ may be formed in surface 5010 a′″. Trougharea 5010 a′″ may be formed by milling out the material from surface5010 a′″ using conventional milling apparatuses and methods. Trough area5010′″ may be configured to receive therein a cooling channel module5019′.

Cooling channel module 5019′″ may have one or more cooling channels5030′″ (FIG. 26J) with respective input and output ports for connectingto corresponding ports to channels 5020/5021 in base block 5000 suchthat cooling fluid can flow through cooling channels 5030′″, in a manneras described above . The configuration for the cooling channel in acooling channel module 5019′″ may vary and may be designed to providedesired cooling in the particular configuration of cavity wall surface5011. The cooling channel module 5019′″ may have an outer generallyrectangular framework with side frame members and a base that supportthe cooling channels therein. The outer framework may provide a frictionfit of the cooling channel module 5019″ with the vertical walls oftrough area 5010′″.

In each embodiment where a mold cavity block is manufactured as aseparate piece to the base block (such as mold cavity block 5010″ andbase block 5000″ or cavity block 5010′″ and base block 5000′″) a sealingring may be provided on the opposed mating surfaces of the cavity blockand base block around the water fittings to provide a water seal. Forexample, as shown in FIG. 26J a sealing o-ring 5022 made from a suitablematerial such as a suitable rubber may be provided between the moldcavity block 5010′″ and base block 5000′″ to provide a fluid sealbetween mold cavity blocks 5010′″ and base blocks 5000′″. Internalsealing within mold cavity block 5010′″ and cooling channel module5019′″ is typically not required.

The result is that a standard configuration for a surface topography5012′″ defining the trough area 5013′″ can be milled on the cavity sidesurface of a cavity mold block 5010′″ and then a particularly configuredcooling channel module 5019″ can be inserted therein to provide thedesired specific cooling channel configuration for the particular cavitywan surface configuration for the particular item to be molded. Thisenhances the efficiency of the manufacturing process. The components ofcooling channel module 5019′″ may be formed from any one or moresuitable material(s) such as copper or stainless steel or a suitableplastic such as PP (polypropylene) or PE (polyethylene).

With reference to FIG. 28A, a sequence of steps (a) to (f) is shown bywhich a services block 5196 and a cavity plate 194 may be connected to aplaten 196. In the first steps (a) to (c), a services block 5196 ismounted to a platen 196. Services block 5196 may be connected to aplaten 196 by threaded bolts 5197 being received through openings 5198in services block 5196 and into threaded openings 5195 in platen 196.

In step (d) a pre-prepared cavity plate 194 which may comprise a baseblock 5000 and a mold cavity block 5010, 5010′, 5010″ or 5010′″, is madeavailable to be connected to the services block 5196. A quick connectionof the type described above may be utilized to connect the base block5000, and thus cavity plate 194, to the services block 5196 to provide aplaten and cavity plate assembly shown in (f) of FIG. 28A.

During operation of a mold sub-assembly 3040, 3040′ as describedelsewhere herein, the platen pairs 196 will have at least one servicesblock 5196 attached thereon. One or more mold cavity plates 194 will beattached to a services block 5196. The cavity plates 194 may comprise abase block 5000 and a mold cavity block 5010, 5010′, 5010″ or 5010′″,and may produce molded items within the mold cavities formed betweenopposed pairs of mold cavity blocks 5010, 5010′, 5010″ or 5010′″.Cooling fluid and/or other services may be provided from the platens 196to a services block 5196 and onto the base blocks 5000 and theircorresponding mold cavity blocks 5010.

When it is desired to change the type of molded item being produced byparticular mold cavity plate 194 of a mold sub-assembly 3040, 3040′, thequick connection mechanism associated with the appropriate pair ofcavity plates 194 can be operated to disconnect the base block 5000 fromthe services block 5196 with the quick connection mechanism, along withthe currently being used mold cavity blocks 5010 attached to the baseblock 5000. A replacement cavity plate 194 can then be installed byconnecting the base block 5000 to that services block 5196 with a quickconnection mechanism, to thereby connect a replacement mold cavityblocks 5010 attached to the replacement base block 5000. The replacementpairs of base blocks 5000 and their respective mold cavity blocks 5010,5010′, 5010″ or 5010′″ may be configured to produce a differenttype/shape molded item than the removed pairs of base blocks and moldcavity blocks 5010, 5010′, 5010″ or 5010′″.

Transfer of Material to Shaper

With primary reference to FIGS. 29-37, details of example features fortransferring molding material into a shaper will now be described.

FIG. 29 depicts a partial cross-sectional view of vessel 124 and aportion of cavity plate 194 of mold 200. As shown, orifice 136 of vessel124 is aligned with a gate passage 2002, through which feedstock isinjected into mold 200. In order for such injection to occur, sealingmember 140 is withdrawn to un-seal orifice 136. Injection is then causedby driving piston 182 towards orifice 136 to reduce the volume of cavity134 and force molding material out through orifice 136.

During injection of feedstock into mold 200, the tip of vessel 124 matesto a corresponding recess defined in cavity plate 194 proximate gatepassage 2002. Vessel 124 is heated to a temperature corresponding tothat of molten feedstock. Mold 200 is maintained at a coolertemperature, e.g. ambient temperature, to promote rapid cooling andsolidification of feedstock after injection into the mold 200.

Typically, it is desirable for molten feedstock to be maintained at atarget elevated temperature until immediately prior to injection, andthen to subject the feedstock to a significant thermal gradient in orderto rapidly cool and solidify the material within the mold. Such thermalcontrol may maintain flowability of the feedstock during injection, toachieve uniform filling of the mold. Moreover, such treatment may ensuredesired product characteristics. For example, rapid cooling tends tolimit or prevent crystallization of feedstock, providing desiredstrength and appearance characteristics in finished parts. Such rapidcooling may be achieved by maintaining mold 200 at a low temperaturerelative to the molten feedstock.

Insulator 1332 and cap 1334 help maintain the desired thermal gradientat the interface of vessel 124 and mold 200. Specifically, as noted,insulator 1332 has low thermal conductivity and thus presents a barrierto heat transfer between with tip 1322 of vessel 124 and mold 200.

In contrast, cap 1334 has relatively high thermal conductivity and tendsto promote cooling of sealing member 140 by heat transfer with mold 200.

Referring again to FIGS. 12A-12D, shaping station 104-1 also comprisesan actuator assembly 204, aligned with the injection assembly andaligned with axis M-M. Actuator assembly 204 includes a vesselpositioning actuator (not shown) and an injector 210. The vesselpositioning actuator can be extended to urge vessel 124 into abutmentwith mold 200. In this position, gate orifice 136 of vessel 124 alignswith mold inlet gate 202 of mold 200.

Shaping station 104-1 may also comprise a valve locking assembly. Thevalve locking assembly may serve as a trigger for releasing sealingmember 140 from its sealing position. FIG. 30 is a series ofcorresponding isometric and overhead views showing the operation of anexample valve locking assembly 2080.

Valve locking assembly 2080 includes a cam guide 2082 with a slot 2084for receiving a bearing 1276 rigidly mounted to movable arm 1272 ofcarrier 125. Bearing 1276 is received in slot 2084 as carrier 125 movesvessel 124 toward molding axis M-M of the shaping station. The directionof motion of the carrier 125 and vessel 124 is indicated by the arrow Din FIG. 36.

Slot 2084 has a profile such that it acts as a cam for bearing 1276 andarm 1272. That is, as the carrier 125 and vessel 124 progress towardmolding axis M-M, slot 2084 causes bearing 1276 and arm 1272 to pivotfrom an initial position in which arm 1272 engages sealing member 140,holding the sealing member in its sealing position, toward a finalposition in which arm 1272 clears sealing member 140 such that thesealing member can be displaced from its sealing position.

With arm 1272 clear of sealing member 140, sealing member 140 can bepushed downwardly into vessel 124, clearing the occlusion of orifice 136and allowing molten molding material to be transferred into the vessel124. Sealing member 140 may, for example, be retracted by way of anactuator positioned above or below vessel 124, or by the pressure of themolten molding material acting on sealing member 140 through orifice136.

As shown in FIGS. 7 and 30, closure assembly 1270, including movable arm1272 and bearing 1276 are located at the bottom of carrier 125. However,in other embodiments, the closure assembly may be located at the top ofthe vessel.

For example, FIG. 31 depicts a carrier 125′ with a top-mounted closureassembly 1270′, movable arm 1272′ and bearing 1276′. In the depictedembodiment, cam guide 2082 with slot 2084 is likewise positioned atopcarrier 125, above vessel 124. Movable arm 1272′ externally occludesorifice 136. Thus, arm 1272′ functions as a sliding gate to seal orifice136. That is, as arm 1272′ moves towards a closed position, the armslides over the top of vessel 124. In this embodiment, sealing member140 may be omitted from vessel 124 or alternatively, may provideredundant sealing along with movable arm 1272′.

Referring to FIGS. 12A-12D, injector 210 of actuator assembly 204 can beextended to act against piston 182 of vessel 124, urging piston 182towards gate orifice 136 and expelling molten feedstock out of cavity134 through gate orifice 136. Injection of feedstock into mold 200 andsubsequent cooling of the feedstock forms a molded workpiece 101′.

A second track 144 of transport subsystem 110 passes through an ejectionposition below shaping station 104-1 and aligned with ejection axis E-E.

A carriage 129 is received on track 144 and is slidable along the track,e.g. by electromagnetic, pneumatic or mechanical manipulation. Transportsubsystem 110 is capable of indexing individual carriages to specificlocations on track 144. For example, transport subsystem may comprisesensors or encoders (not shown) for repeating the precise position ofcarriage 129.

Carriage 129 includes a workpiece grip 131 for physically holding aworkpiece to the carriage. As depicted, grip 131 comprises a nest whichmay be shaped to receive the molded workpiece 101′. In some embodiments,the nest may have a shape that is complementary to workpiece 101′. Inother embodiments, the nest may not be precisely complementary to anyspecific workpiece 101; but may instead have a shape, e.g. a concavecurve, designed to securely receive workpieces in a range of shapes andsizes. Suction may be applied to the nest to draw workpiece 101′ againstcarriage 129. An actuator assembly 201 is located at the ejectionposition, and is operable to extend and push carriage 129 toward mold200 so that the nest 133 is positioned immediately adjacent mold 200.

Tracks 144 of transport subsystem 110 are offset from one another toprovide clearance for carriages 125, 129 and workpiece 101′ and vessel124. The offset between the tracks may be one or both of horizontal andvertical.

FIG. 32 depicts actuation assembly 204 of shaping station 104-1 ingreater detail. In some embodiments, injection stations of dispensingcell 102 may have actuation assemblies substantially similar toactuation assembly 204. Actuation assembly 204 includes a carriage 2040for supporting a vessel 124 proximate mold 200. Carriage 2040 is movablerelative to mold 200 by linear drives (e.g. servos or hydraulic pistons)2042.

Carriage 2040 has a nest 2044 mounted thereto, for receiving a vessel124. Nest 2044 is positioned adjacent track 144 such that a vessel 124can be transferred onto nest 2044 by a carriage 125 travelling alongtrack 144 as indicated by arrow Tin FIG. 38.

FIGS. 33A, 33B and 33C are isometric, cutaway isometric andcross-sectional views, respectively, showing details of nest 2044 and avessel 124.

As shown, nest 2044 has an opening 2045 to receive the base of a vessel124. The nest 2044 has side walls that project upwardly but are sized toprovide clearance for tongs 1254 (FIG. 7A, 7B), such that vessel 124 maybe inserted in nest 2044 while gripped by tongs 1254.

Nest 2044 has a locking projection 2046 sized and positioned tointerlock with detent 1256 of vessel 124. Projection 2046 may besemi-annular in shape. As vessel 124 is inserted in nest 2044,projection 2046 is received in detent 1256 and retains the vessel innest 2044.

Although closure assembly 1270 and valve locking assembly 2080 are notshown in FIGS. 32, 33A and 33B, it should be understood that valvelocking assembly 2080 is positioned proximate nest 2044, such that itcauses arm 1272 to pivot clear of nest 2044 prior to or concurrentlywith insertion of vessel 124 into nest 2044 (see FIG. 30).

Nest 2044 comprises a channel 2048 for receiving the base of sealingmember 140, including detent 180.

The bottom of nest 2044 is open to permit interaction of actuationassembly 204 with the body of vessel 124 and with sealing member 140 andpiston 182. Specifically, in the depicted embodiment, actuation assembly204 includes actuators, e.g. pneumatic or servo-driven pistons,cylinders or the like, that can extend through the bottom of nest 2044to act against the body of vessel 124, sealing member 140 or piston 182.

With reference to FIG. 33C, actuators for acting against vessel 124,sealing member 140 and piston 182 may be in a nested (e.g. concentric)arrangement. Specifically, a hollow vessel locking actuator 2062 ispositioned to abut the base of vessel 124. A flow actuator, namely,injection actuator 2102 is nested within vessel positioning actuator2062. A gate operating actuator 2104 is in turn nested within injectionactuator 2102.

Vessel locking actuator 2062 and injection actuator 2102 may be tubular,i.e. with annular top and bottom surfaces. The top surfaces of actuator2062 and 2102 (i.e. the surfaces closest to orifice 136 along thelongitudinal axis) abut vessel 124 and piston 180, respectively. Gateoperating actuator 2104 may include a gripping feature 2106 with a notenshaped to receive and interlock with detent 180 of sealing member 140.

In the depicted embodiment, vessel locking actuator 2062 and gateoperating actuator 2104 are pneumatically driven and injection actuator2102 is servo-driven. However, each actuator may be driven by anysuitable drive type.

As will be explained in further detail, vessel locking actuator 2062 isoperable to bias vessel 124 toward mold 200, such that the tip of vessel124 tightly abuts the mold. In such condition, vessel 124 is loadedagainst projection 2046 of nest 2044.

In the depicted embodiment, gate operating actuator 2104 includes afirst section 2105 and a second section 2107, which are coupled by acoupling pin 2109 that extends through a slot defined in the injectionactuator 2102. Specifically, pin 2109 may be extended through holes infirst and second sections 2105, 2107, to couple the sections such thatthey extend together. In the depicted embodiment, first section 2105 isa generally hollow tubular element whereas the second element is agenerally cylindrical member. First section 2105 has an internaldiameter to accommodate independent sliding motion of the injectionactuator 2102 nested therein.

Similarly, the injection actuator 2102 is a tubular member with aninternal diameter to accommodate the second section 2107 of the gateoperating actuator 2104 nested therein.

Gate operating actuator 2104 is operable to extend sealing member 140into its sealing condition, in which the sealing member 140substantially prevents flow of material through orifice 136, and toretract the sealing member 140 to open orifice 136.

As noted, in the depicted embodiment, injection actuator 2102 is drivenby a servo. Servo drive of injection actuator 2102 may allow for largeforces to be applied, to subject molding material to suitable injectionpressure, with relatively high positional accuracy of injection actuator2102, and thus, of piston 182. Other suitable drives may be used inother embodiments. For example, in some embodiments, injection actuator2102 may be hydraulically driven.

Injection actuator 2102 is operable to act against piston 182 to forcemolding material out of vessel 124.

FIGS. 34A-34K depict shaping station 104-1 at various stages of ashaping operation. For simplicity, core positioning actuator 1046 andloading actuator 1050 are omitted from FIGS. 34A, 34B-34C, 34E, 34I and34J.

As shown in FIG. 34A, a carriage 125 carrying a vessel 124 istransported on track 144 to the injection position facing injectionstation 104-1 and aligned with mold axis M-M. Orifice 136 of vessel 124is opened as carriage 125 and vessel 124 are moved into position atmolding axis M-M, for example, as described above with reference to FIG.30. Once in position the vessel locking actuator 2062 extends to lockthe vessel 124 in the injection station 104-1.

As shown in FIGS. 34B-34C, core assembly 190 is moved to align with moldaxis M-M and cavity plate 194-2. Platen 196-1 is moved toward platen196-2 and clamps mold 200 in a closed position.

As shown in FIG. 34D, camshaft 3154 of load actuator 3050 rotates tourge moving plate 3142, loading frame 3104, and core 190 downwardly. Themoving plate 3142, loading frame 3104 and core 190 move through a shortstroke. In the depicted example, the length of the stroke is about 2 mm.A downward force is exerted on loading frame 3104 and core 190 to resistpressure from injection of molding material into mold 200. The downwardforce may be referred to as a pre-load. In the depicted example, thepre-load is about 60 kN.

Linear drives 2042 retract to move carriage 2040 toward mold 200 suchthat the coupling assembly of the vessel sealingly abuts with the moldplates of the mold 200 and the orifice 136 of vessel 124 aligns withgate 202 of mold 200. The linear drives also controls the contact force(effectively the sealing force) between the mold and vessel. Gateoperating actuator 2104 next retracts the sealing member 140 away fromthe mold 200 thereby fluidly connecting the vessel 124 with the moldingcavity.

Injector 210 extends and forces piston 182 towards orifice 136, reducingthe volume of cavity 134 and urging molten feedstock through gate 202and into mold 200. The feedstock cools and solidifies, forming a solidmolded article (FIG. 34E). Gate operating actuator 2104 then extends thesealing member 140 towards the mold 200 closing thereby isolating thevessel 124 from the molding cavity.

As shown in FIG. 34F, once molding is complete, loading actuator 3050causes moving plate 3142, loading frame 3104 and core 190 to moveupwardly through a short stroke. In the depicted embodiment, the strokemay typically be 3 mm or less in length. Camshaft 3154 rotates to bearagainst rocker 3152 and forces moving plate 3142 upwardly. Projections3174 of moving plate 3142 bear against load frame 3104, moving the loadframe upwardly. Inner core 3112 moves upwardly with load frame 3104. Theforce applied to inner core 3112 during the upward stroke may berelatively large. In some embodiments, the force may be similar inmagnitude to the preload created by load actuator 3050 prior to molding.The upward movement dislodges the molded article from inner core 3112.That is, it forms a small initial crack between the molded article andinner core 3112.

As shown in FIG. 34G, mold 200 is moved to its open state by clampingsubassembly 3042 retracting platen 196-1 and cavity plate 194-1 fromplaten 196-2 and cavity plate 194-2.

As shown in FIG. 34H, secondary mold opening actuator 3180 extends tomove the core assembly 190 away from platen 194 so that core assembly190 is aligned with ejection axis E-E (FIG. 39G).

Carriage 129 is extended upwardly so that its nest is positionedimmediately below molded workpiece 101′ and suction is applied throughnest to assist in drawing molded workpiece 101′ off of core assembly190. Carriage 129, carrying molded workpiece 101′, is then moved alongtrack 144 for further processing.

Workpiece 101′ may be removed from core assembly 190 by retracting theinner core 3112 away from carriage 129 along ejection axis E-E.Specifically, cylinders 3108 of core positioning actuator 3046 extend tomove load frame 3104 and inner core 3112 away from outer core 3114 andcarriage 129. As inner core 3112 retracts, outer core 3114 bears againstthe workpiece and pushes the workpiece off core assembly 190 as the coreretracts.

FIGS. 35A-35F show operation of actuation assembly 204 in greaterdetail. FIGS. 35A-35F are isometric cutaway views, which are cut away ata 90 degree angle to the views of FIGS. 33B-33C. As shown in FIG. 35A,once vessel 124 is moved into position on nest 2044, vessel lockingactuator 2062 is extended, which biases vessel toward mold 200 andagainst projection 2046 of nest 2044. As mentioned previously, lineardrives then retract to move carriage toward mold such that the vesselsealingly abuts the mold plates of the mold and the orifice of vesselaligns with gate of the mold.

As shown in FIG. 35B, injection actuator 2102 is extended into contactwith piston 182. As shown in FIG. 35C, gate operating actuator 2104retracts and sealing member 140 retracts from its sealed position to itsopen position, in which molding material is free to flow through orifice136.

Once sealing member 140 has been retracted to unseal orifice 136,injection actuator 2102 is extended through a stroke as shown in FIG.35C to force molding material out of vessel 124 and into mold 200. Thestroke may be a specific length, as defined by the drive mechanism ofinjection actuator 2102, or the stroke may continue until piston 182abuts vessel up 1322. Thus, the amount of material forced out of vessel124 may be determined by injection actuator 2102 or its drive mechanism,or by the internal volume of vessel 124.

Orifice 136 is resealed by extension of sealing member 140 as shown inFIG. 35E. That is, the gate operating actuator 2104 extends, movingsealing member 140 into a sealing position.

Following completion of injection, injection actuator 2102 may bewithdrawn as shown in FIG. 35F. As depicted, piston 182 may remain inits extended position following retraction of injection actuator 2102.For example, piston 182 may be maintained in its position by friction.In other embodiments, piston 182 may be retracted along with injectionactuator 2102.

In an alternative embodiment, as depicted in FIG. 36, the shapingstation 106-1 may further include a gate assembly 2200 provided betweenvessel 124 and mold 200 for selectively cutting a vestige of injectedfeedstock between vessel 124 and mold 200 after injection of the moldingmaterial is complete. The gate assembly 2200 is particularly useful whenused in conjunction with a vessel without a sealing member 140 asmentioned previously. When used with the vessel 124 having a sealingmember 140 the gate assembly 2200 nonetheless may assist with trimmingof the vestige formed on the base of the preform prior to demolding.Gate assembly 2200 may comprise a plate 2202, which may be mounted belowmold 200, and a blade 2204. Blade 2204 may be received in a pocket 2206defined in plate 2202. As depicted, blade 2204 has an archedcross-sectional shape. The arched portion of blade 2204 is compressedwithin pocket 2206 between plate 2202 and mold 200. Compression of blade2204 biases the blade against the lower surface of mold 200 such thatthe blade fits tightly against mold 200. However, in other embodiments,blade 2204 may have different cross-sectional shapes. For example, blade2204 may be substantially flat. Gate assembly 2200 may also include ascraper 2208 positioned to rub against the underside of blade 2204 as itextends and thereby dislodge residual molding material from theunderside of the blade. In the depicted embodiment, scraper 2208 isserrated. In other embodiments, scraper 2208 may have a straight edge.

FIGS. 37A-37B are cross-sectional views showing a process of cutting astream of molding material between vessel 124 and mold 200. The processmay occur immediately after injection of molding material into mold 200is completed. As shown in FIG. 37A, blade 2104 is advanced toward thestream of molding material, which may be partially or fully solidified.

As shown in FIG. 37B, blade 2104 cuts the stream of molding material,thereby parting the article within mold 200 from any residual moldingmaterial outside mold 200 or within vessel 124. After such parting,vessel 124 may be withdrawn from mold 200. Blade 2104 then extends pastscraper 2108 to dislodge molding material, if any, from the underside ofthe blade.

FIG. 38 depicts a conditioning cell 108 and shaping cell 106 in greaterdetail. As shown, stations of conditioning cell 108 and stations ofshaping cell 106 are located in close proximity to one another. That is,conditioning station 108-1 and shaping station 106-1 are located closetogether.

Thermal Conditioning

With primary reference to FIGS. 39-40, details of an exampleconditioning cell 108 will now be described.

In the depicted embodiment, conditioning cell 108 is for creating adesired thermal profile by heating a molded workpiece in order toprepare the workpiece for a subsequent shaping operation at shaping cell106. For example, stations of conditioning cell 108 may be configured toheat or cool a workpiece, changing its overall temperature; or to changethe temperature distribution in a workpiece by preferentially heating orcooling some regions of the workpiece; or a combination thereof.

FIG. 39 shows a cross-sectional view of conditioning station 108-1.Conditioning station 108-1 includes a frame 400 and a heat-generationassembly 402, a heating chamber 404, a thermal monitoring system 406,and a mandrel 408, all of which are supported on the frame 400.

Heat-generation assembly 402 includes a device for applying heat to areceived workpiece. In some embodiments, heating may be achieved byexposing the workpiece to microwave radiation. In other embodiments,heating may be achieved by directing infrared light onto the workpiece.Other suitable techniques may be used in other embodiments. For example,a workpiece may be immersed in a heated fluid such as air.

Heat generation assembly 402 may include one or more thermal meteringdevices 410. Thermal metering devices 410 are operable to control therate at which heat is applied to a workpiece. For example, thermalmetering devices 410 may comprise wave tuners for influencingcharacteristics of microwave radiation, e.g. by altering a standing wavepattern of radiation within chamber 404 to control the position ofhigh-radiation regions relative to a workpiece within the chamber.Alternatively or additionally, thermal metering devices 410 may compriseshields to partially or fully block incident radiation, or valves toregulate the flow of heated fluid.

Heating chamber 404 is configured to receive the workpiece, and heatfrom heat-generation assembly 402 is directed towards heating chamber404, such that the temperature of the workpiece increases while itresides in heating chamber 404. In some embodiments, heat may be appliedfocally to specific areas of the workpiece, in order to produce aspecific desired temperature profile. The overall (e.g. average)temperature of the workpiece may increase, remain static, or decrease.For example, in some embodiments, portions of the workpiece may bepermitted to cool while heat is retained in or added to other portions.Thermal metering devices 410 may provide for control of the heatdistribution and resulting temperature profile.

Mandrel 408 is mounted to frame 400 and is rotatable about its axis andmovable in three dimensions.

Mandrel 408 has a grip assembly 412 configured to releasably engage aworkpiece. As depicted, grip assembly 412 has a fixed block 414 and amovable block 416. Fixed block 414 is rigidly supported on mandrel 408.Movable block 416 is mounted to a linear actuator 418, which is in turnmounted to mandrel 408.

A compressible member 415 is positioned between fixed block 414 andmovable block 416. Linear actuator 418, thereby axially compressing thecompressible member 415, can retract movable block 416. Axialcompression of the compressible member 415 causes a radial expansion ofthe member into contact with an interior wall of workpiece 101. Thecompressible member 415 frictionally engages the workpiece, and therebyretains the workpiece on the mandrel 408.

Movable block 416 has a tapered leading surface, which at its widestextent is sized for slight interference with a cavity of workpiece 101′.Movable block 416 may be extended into workpiece 101′. Such extensionrelieves strain in compressible member 415, allowing it to rebound toits original shape and release workpiece 101′. Extendable block 416 canthen push workpiece 101′ off mandrel 408.

Heating chamber 404 has a top opening 422 through which mandrel 408 canlower a workpiece into the chamber. Thermal monitoring system 406comprises temperature probes 407 proximate top opening 422, to measureand record a temperature profile of a workpiece entering heating chamber404. In the depicted embodiment, four temperature probes 407 arepresent, and are spaced evenly around top opening 422. The depictedtemperature probes 407 are infrared cameras. In other embodiments, othertypes of temperature measuring devices may be used. For example,temperature probes may include thermocouples. Other suitabletemperature-measuring devices may be used, as will be apparent toskilled persons.

FIGS. 40A-40C depict conditioning station 108-1 at various stages of aconditioning operation. FIG. 40C shows the conditioning station 108-1 incross-section to show internal components.

As shown in FIG. 40A, a workpiece 101′ is delivered to conditioningstation 108-1 by a carriage 129 travelling along track 144. Carriage 129is moved to a carriage loading position.

As shown in FIG. 40B, mandrel 408 is positioned over workpiece 101′,with grip assembly 412 received inside the workpiece. Movable block 416of grip assembly 412 is retracted toward fixed block 414 to squeezecompressible member 415 against the workpiece. Friction betweencompressible member 415 and workpiece 101′ holds the workpiece tomandrel 408.

Mandrel 408 moves workpiece 101′ into position proximate top opening 422of heating chamber 404 and then, as shown in FIG. 40C, passes workpiece101′ into the heating chamber 404. A treatment is applied to theworkpiece 101′. Specifically, heat is generated by heat generationassembly 402 and applied to the workpiece within heating chamber 404.

Once treatment of workpiece 101′ has been completed, mandrel 408withdraws the workpiece 101′ from heating chamber 404.

Secondary Shaping

With primary reference to FIGS. 41-51, features and operation of examplestations of an example shaping cell 106 and a mold for the shaping cellwill now be described in detail. In the depicted embodiments, theexample stations are for blow molding of plastic articles. However, manyfeatures of the described embodiments are not limited to blow molding,as will be apparent.

FIGS. 41A-41B show a shaping station 106-1 of shaping cell 106 ingreater detail.

As depicted, shaping station 106-1 is a stretch blow-molding station,for forming a hollow container from a molded workpiece. In analternative embodiment, not shown, the shaping station is aliquid-molding station, wherein the operation of forming and filling ofa container are combined. Station 106-1 includes a mold 500, defined bya plurality of mold sections 502-1, 502-2, . . . 502-n (individually andcollectively, mold sections 502). In the depicted embodiment, mold 500includes two sections 502-1, 502-2 and a bottom plug 503. However, moreor fewer sections may be present.

Mold sections 502 are mounted to respective platens 504 of a press 506.Some or an or mold sections 502 are mounted to movable platens, so thatthe mold 500 can be opened to allow insertion of a workpiece or removalof a completed part, and so that the mold 500 can be clamped shut duringmolding.

Press 506 is mounted to a support frame 510 which is in turn removablymounted to a base 512. A clamping assembly 514 is mounted to supportframe 510 and platens 504 are fixed to clamping assembly 514 for openingand closing of the platens.

Clamping assembly 514 is shown in greater detail in FIG. 47. In thedepicted embodiment clamping assembly 514 has two linkages 516, eachcoupled to a respective platen 504.

Each linkage 516 is substantially identical to linkage 3070 depicted inFIG. 12D and has a drive link 518 and rockers 520, 522. Drive link 518is coupled to a crosshead 524 which is driven in reciprocating motion bya linear actuator, such as a ball screw driven by an electric motor 526.

In other embodiments both platens may be driven by a single linkage. Forexample, the linkage may be substantially identical to any of linkages3070′, 3070″, 3070′″, 3070″″.

Press 506, mold sections 502 and bottom plug 503 may be installed to andremoved from a support base as a unitary assembly, substantially asdescribed above with reference to shaper module 3054 of shaping station104-1.

Shaping cell 106 is located close to conditioning cell 108 and lieswithin an area reachable by mandrel 408, such that mandrel 408 is ableto reach stations of conditioning cell 108 as well as stations ofshaping cell 106. In other words, mandrel 408 is capable of removing aworkpiece from heating chamber 404 of conditioning station 108-1 andplacing the workpiece in mold 500 of shaping station 106-1 for moldinginto a container.

A molding head 504 is mounted on a second mandrel 506 and is operable toinject pressurized fluid into a workpiece within mold 500 to expand theworkpiece to conform to the mold. Molding head 504 has a grip assemblysimilar to grip assembly 412 of mandrel 408. The grip assembly comprisesfixed and moving blocks 510, 512 and a compressible member 514 tofrictionally grip workpiece 101′ when squeezed between blocks 510, 512.Molding head 504 further comprises a fluid injection passage extendingalong an axis of mandrel 506 through which pressurized fluid (e.g. airor liquid) can be injected into workpiece 101′.

FIGS. 42-43 depict components of shaper station 106-1 in greater detail.As noted, mold 500 includes mold sections 502-1, 502-2 and a bottom puck503. Mold sections 502-1 and 502-2 are mounted to platens 196 which aresupported on a shaper frame 8052. Platens 196 are movable by a clamp8070 between open and closed positions. In the closed position, moldsections 502-1, 502-2 and bottom puck 503 mate to cooperatively define amold cavity 8000. In the open position, platens 196 are spaced apart. Ina first mode, mold sections 502-1, 502-2 are coupled to the platens sothat a molded part may be removed. In a second mode, mold sections502-1, 502-2 are de-coupled from platens 196, so that they can beremoved as an assembly.

Shaper frame 8052 and clamp 8070 are substantially identical to shaperframe 3052 and clamp 8070.

Multiple interchangeable molds 500 may be present, each comprising a setof mold sections 502-1, 502-1 and bottom puck 503. Each mold defines aspecific mold cavity 8000 in operation, for forming parts of a specificconfiguration. For example at any given time, a single mold 500 may beinstalled to platens 196 of a shaper station 106-1. The mold 500 may beinterchanged with another mold, for example, to produce parts of adifferent configuration or for maintenance or repair.

Each mold section 502 is removably mounted to services block 8004. Eachservices block 8004 is in turn mounted directly to platen 196. Moldsections 502 may be formed of a relatively lightweight material such asan aluminum alloy. Services blocks 8004 may be formed of a suitable toolsteel or a high-strength aluminum alloy.

During molding (as shown in FIGS. 42-43), clamp 8070 exerts a closingforce on the mold 500. The closing force urges mold sections 502 againstone another and provides mold conditions consistent with high-qualitymolded articles. However, mold sections 502 tend to be formed ofrelatively low-strength material. Accordingly, services blocks 8004 haveload limiting features, namely, load limiting blocks 8005 formed in theopposing faces of services blocks 8004. Under nominal moldingconditions, load limiting blocks 8005 are spaced apart by a smallmargin. However, in the event that the load applied by clamp 8070 isexcessive, mold sections 502 may deform or compress incrementally, suchthat load limiting blocks 8005 abut one another. In this condition, loadlimiting blocks 8005 bear at least part of the clamping load, and thusprotect against further deformation of mold sections 502.

FIGS. 44 shows an isometric view of mold 500 and services blocks 8004,with services blocks 8004 exploded from mold sections 502. FIG. 45 showsan isometric view of mold 500 with mold sections 502 and puck 503exploded from one another. As depicted, each mold section 502 has ahalf-cylindrical outer surface and an inner surface 8012 shapedaccording to the desired configuration of mold cavity 8000 (and thus, ofthe produced parts).

Each mold section 502 has a support ledge 8014 at its top surface. Eachsupport ledge 8014 is generally annular. In the closed position, withmold sections 502 abutting one another, the support ledges 8014cooperate to define a mold opening. A preform from shaper cell 104 maybe supported on support ledges 8014, such that a neck ring of thepreform abuts support ledges 8014 and the preform extends into moldcavity 8000.

Mold sections 502 have handling studs 8020 which extend outwardly fromtheir outer surfaces. Handling studs 8020 have connectors 8022 forengagement by a material handling device such as a robot. Mold sections502 additionally have connectors 8024 on outer surfaces 8010 which, inoperation, face towards services blocks 8004. As which be explained infurther detail, connectors 8024 can be selectively engaged withcorresponding connectors on services block 8004 to couple mold sections502 to services blocks 8004.

As shown in FIG. 45, mold sections 502 have recesses 8019 at their lowerends. Recesses 8019 are half-cylindrical and are sized to cooperativelyreceive bottom puck 503 when mold 500 is closed (see FIG. 46).Semi-annular retaining flanges 8021 project inwardly from the walls ofrecesses 8019. When mold 500 is closed, flanges 8021 are received by andinterlock with puck 503. Thus, puck 503 is captive as part of mold 500when the mold is closed.

Each services block 8004 has a mold-facing surface 8030 and a rearsurface 8032. Rear surface 8032 is shaped to mate to platen 196 andmold-facing surface 8030 is shaped to mate to the outer surface 8010 ofa mold section 502. In the depicted embodiment, rear surface 8030 isgenerally planar and cavity block-facing surface 8030 is generallyhalf-cylindrical.

Rear surface 8032 has a plurality of connectors 8034 which, inoperation, align to corresponding connectors of platen 196. In thedepicted embodiment, the connectors between services block 8004 andplaten 196 are fasteners such as bolts. Dowels (not shown) may beinstalled to locate services block 8004 relative to platen 196.

Cavity block-facing surface 8032 has connectors 8036 which, inoperation, face towards the corresponding mold portion 502 and alignwith connectors 8024. As noted, connectors 8036 and connectors 8024 mayselectively engage one another to lock mold section 502 and servicesblock 8004 together.

In the depicted embodiment, services blocks 8004 also has servicesconnections. For example, electrical circuits connect sensors such asthermocouples, and power heating elements. Pneumatic circuits are beused to drive actuators, e.g. to control quick connection mechanisms.Water circuits provide cooling. As depicted, cooling and pneumaticservices need not be routed to mold sections 502. Rather, pneumaticoperation of connectors 8024/8036 is provided within services blocks8004. Cooling fluid flows in a circuit through services blocks 8004,which cool mold sections 502 are cooled by conduction. In someembodiments, services connections are routed to lateral sides ofservices blocks 8004. Alternatively or additionally, servicesconnections may be routed through platens 196 or through a discretedistribution plate mounted between each platen 196 and services block8004.

In other embodiments, in addition to physical coupling by way ofconnectors, 8024, 8036, mold sections 502 and base plates 8004 may beconnected with one or more services such as electrical, pneumatic andwater circuits. For example, liquid cooling circuits may be defined inmold sections 502 and pneumatic lines may be defined in mold sections502 for operation of connectors.

Services blocks 8004 have auxiliary pneumatic ports 8037, 8039.Auxiliary pneumatic ports 8037, 8039 are for providing a supply ofpressurized air to operate connectors 8036. Port 8037 is for receiving apressurized stream to center connectors 8036, 8024 relative to oneanother. That is, with a connector 8024 and a connector 8036 coupledtogether, a stream of pressurized air may be provided to port 8037 tobriefly unload the connectors. Upon release of the pressurized air, theconnectors return to nominal locked positions. Port 8039 is forreceiving a pressurized stream of air to disengage connectors 8036, thatis, to bias them to a released state in which connectors 8024 can befreely removed.

Referring to FIG. 46, bottom puck 503 comprises a puck cavity block8050, a puck base block 8053 and a connecting block 8054. Connectingblock 8054 is in turn connected to an actuator block 8056. Puck 503 ismovable as an assembly along an axis perpendicular to the closing axisof clamp 8070. Such movement may be affected, for example, by one ormore linear actuators mounted beneath actuator block 8056 and supportedon shaper frame 8052. The linear actuators may be, for example, servos,or hydraulic or pneumatic pistons.

Puck cavity block 8050 defines the bottom surface of mold cavity 8000when mold 500 is closed. As will be appreciated, molding occurs atrelatively high temperatures. Once the part has assumed its final shape,it is desirable to quickly cool the part to avoid deformation or otherdefects, and to enable the part to be removed. A thermal regulationcircuit 8058 is defined between puck cavity block 8050 and puck baseblock 8053. Fluid such as water may be circulated through the circuit topromote removal or heat from the molded part or introduction of heat tothe molded part.

Puck base block 8053 is mounted (e.g. bolted) to the underside of puckcavity block 8050. Base block 8053 has an annular lock ring 8060 fittedaround its outer periphery. Lock ring 8060 defines a pocket in whichlocking flange 8021 of cavity blocks is received when mold 500 isclosed, thereby locking base block 8053 connecting block 8054 and puckcavity block 8050 to mold sections 502.

Connecting block 8054 is mounted (e.g. bolted) to base block 8053.Connecting block 8054 has a connector 8062 on its underside which facesactuator block 8056 in operation. connecting block 8054 further has oneor more ports for services, such as pneumatic, cooling and electricalcircuits. A flow path for cooling fluid extends from the port throughbase block 8053 and connecting block 8054 to cooling circuit 8058.Connecting block 8054 and actuator block 8056 may connect in fluidcommunication by way of quick-connection ports that couple to oneanother upon being brought together. Coupling may be automatic, e.g.electronically triggered and operated or spring-loaded and triggered byinsertion.

Connector 8062 is received in a corresponding socket 8064 of actuatorblock 8056 (FIG. 43). Actuator block 8056 is configured to mate withlinear actuators for movement of puck 503. Any of connectors 8024, 8036,8062, 8064 may be quick connectors. That is, any of connectors 8022,8024, 8034, 8036 and may form quick connection mechanisms with theircounterpart connectors. Such quick connection mechanisms may havecharacteristics as previously described above.

In the depicted embodiment, the quick connection mechanisms comprisestuds projecting from mold sections 502 towards mating sockets definedin services block 8004, and connectors 8062 which are studs projectingfrom connection block 8054 towards mating connectors 8064 which aresockets defined in actuator block 8056.

As described above, the sockets are operable in engaged and disengagedstates. In the disengaged state, a stud may freely pass into or out ofthe socket. In the engaged state, grippers in the socket are biased intointerlocking engagement with the studs. The studs may be shaped suchthat interlocking by a socket biases a stud into a precise positionrelative to the socket. In other words, the quick connection mechanismsmay locate mold sections 502 and services blocks 8004 relative to oneanother, as well as retaining them together.

The sockets of the quick connection mechanisms may, for example, bespring-biased to one operating state (e.g. the engaged state), and maybe shifted to the other state (e.g., the disengaged state) byapplication of pneumatic pressure. Accordingly, pneumatic supply may berouted to services blocks 8004 for operation of the quick-connectionmechanisms.

In the depicted embodiment, the quick connection mechanisms may besubstantially similar to those depicted in FIG. 4H above. For example,the quick connection mechanisms may be model 305979 and 306050connectors, manufactured and sold by Andreas Maier GMBH & CO. KG (AMF)of Germany. Quick connection mechanisms for services ports such as fluidports may be model 6989N and 6989M connectors, manufactured and sold byAMF.

Conveniently, coupling and de-coupling of mold sections 502 and servicesblocks 8004 by way of quick-connect couplings allows a mold 500 to bequickly and easily removed and substituted with another mold 500.

FIGS. 47-49 depict stages of changing a mold 500.

As shown in FIGS. 47A-47B, platens 196 are held in their closedpositions, with mold sections 502-1, 502-1 abutting one another. Withthe mold in a closed position, material handling devices, namely,gripping plates 8080 mounted on robotic arms (not shown), move towardsthe lateral faces of mold 500. Gripping plates 8080 have connectorscorresponding to handling connectors 8022 of mold sections 502.Specifically, the connectors of gripping plates 8080 are positioned andsized to mate to connectors 8022 of mold sections 502. In the depictedembodiment, connectors are sockets configured to matingly receiveconnectors 8022 to define a quick connection mechanism.

In some embodiments, gripping plates 8080 may approach vertically. Inother embodiments, the gripping plates may approach horizontally.

Once engaged with connectors 8022, as shown in FIGS. 48A-48B, grippingplates 8080 and their associated robot arms are capable of supportingand lifting mold 500 as a unitary assembly. Specifically, mold sections502-1, 502-2 and puck 503 may be removed as an assembly. After grippingplates 8080 engage connectors 8022, pressurized air is provided toauxiliary port 8039 of services block 8004. Application of pressurizedair by way of auxiliary port 8039 causes connectors 8036 to releaseconnectors 8024, thereby de-coupling mold sections 502 from servicesblocks 8004. In the depicted embodiment, the pressurized air is providedfrom a line associated with the shaper station 106-1. Alternatively,supply lines may be associated with gripping plates 8080.

Platens 196 and services blocks 8004 pull away from mold sections 502.Meanwhile, gripper plates 8080 hold mold sections 502 together.

Holding of mold sections 502 in assembly with services blocks 8004likewise holds bottom puck 503 to the assembly. Specifically,semi-annular annular retaining flanges 8021 of mold sections 502 areheld in registration with lock ring 8060 of bottom puck 503.

Connector 8062 of puck connecting block 8054 is released from actuatorblock 8058. The release may be affected, for example, by pneumaticactuation. Once connector 8062 is released, bottom puck 503 may befreely pulled away from actuator block 8058.

Gripping plates 8080 and the associated robot arms may then remove mold500 as a single assembly, shown in FIGS. 49A-49B. Specifically, in thedepicted embodiment, the robot arms lift gripping plates 8080 and mold500 away from services blocks 8004, actuator block 8056 and platens 196.

Installation of a new mold 500 may follow.

Gripping plates 8080 and the associated robot arms interface with andlock to connectors 8022 of another mold 500.

Once the new mold 500 is engaged by gripping plate 8080, the robot armsposition inc new mom in shaper cell 106-1 for mounting of the new mold500 to platens 196. Clamp 8070 then moves platens 196 and servicesblocks 8004 inwardly. Connectors 8024 of mold sections 502 align inregistration with connectors 8036 of services blocks 8004. Connectors8024, 8036 engage and lock together. A pneumatic supply may be providedto auxiliary port 8037 of services block 8004 to seat connectors 8024,8036 together.

Actuator block 8056 is extended upwardly towards connecting block 8054of bottom puck 503. Connector 8064 of actuator block 8056 and connector8062 of connecting block 8054 are aligned with one another. Connector8064 receives and locks with connector 8062 of connecting block 8054.

Once connector 8062 is received by connector 8064, connector 8064 isactuated to a closed shape, e.g. by application of pneumatic pressure.Bottom puck 503 is therefore locked to actuator plate 503.

Once base plates 8004 are coupled to services plates 8006, and bottompuck 503 is coupled to actuator plate 8056, mold 500 can be operated byclamping unit 8070 produce parts according to the configuration ofcavity 8000.

In the depicted embodiment, swapping of molds 500 can therefore beaccomplished relatively quickly and easily, with little or no manualsetup. Indeed, connections between base plates 8004 and mold sections502, and between actuator plate 8056, connecting block 8054, puck baseblock 8053 and puck cavity block 8050, may be entirely automated. Forexample, all of the connectors may be operated by actuators, such thatthey can be simply switched between locked and unlocked states.

Accordingly, shaper station 106-1 can be readily configured for moldinga variety of parts in a variety of different shapes and sizes.

In the depicted embodiment, shaping station 106-1 is a stretch blowmolding apparatus. A rod 520 extends within mandrel 506 and isextendible into workpiece 101′ within mold 500 to mechanically stretchthe workpiece. In other embodiments, stations of shaping cell 106 may befor other types of shaping operations. For example, stations of shapingcell 106 may be any suitable type of blow-molding apparatus.

FIGS. 51A-51D depict mold components of a shaping cell 106-1 at variousstages of a shaping operation.

Mandrel 408 (FIGS. 39-40) carries workpiece 101′ from conditioning cell108-1 to a mold position within mold 500 of shaping cell 106-1. Gripassembly 412 releases the workpiece and mandrel 408 is withdrawn.Mandrel 506 moves to a position proximate mold 500.

As shown in FIG. 51B, mandrel 506 moves toward workpiece 101 and gripassembly 508 extends into workpiece 101′. Compressible member 514 issqueezed into the workpiece to grip it. Rod 520 is extended intoworkpiece 101′ and the workpiece is stretched by rod 520 and injectionof pressurized air to conform to the shape of mold 500 (FIG. 37C). Thestretched workpiece cools and hardens to form a final-shaped workpiece101″, e.g. a hollow container such as a bottle. Mold 500 is opened andworkpiece 101″ is removed by mandrel 508.

Transport Subsystem

With primary reference to FIGS. 52-66, details of example transportationsystems will now be described.

As described above and shown in FIGS. 39-40 and 50-51, shaping cell 106and conditioning cell 108 have associated mandrels 408, 506 that formpart of transport subsystem 110. Each mandrel can reach a conditioningstation 108-1, 108-2, . . . 108-n and a shaping cell 106-1, 106-2, . . .106-n. In other embodiments, mandrels 408, 506 may be longer, such thata single mandrel is capable of reaching multiple conditioning stationsand multiple shaping stations.

In other embodiments, one or both of mandrels 408, 506 may be replacedwith one or more tracks 144. The tracks may include one or more loopsand one or more branches connecting individual conditioning or shapingstations to the one or more loops.

Thus, as depicted, molding material is processed in four stages toproduce a workpiece 101″ such as a bottle. Specifically, moldingmaterial is dispensed at dispensing station 102-1 and shaped into apreform in a primary shaping operation, i.e. injection molding atshaping station 104-1. The preform is heated at conditioning station108-1 to produce a temperature profile suitable for blow molding, andthe heated preform is shaped into a final shape in a secondary shapingoperation, i.e. stretch blow molding at shaping station 106-1.

The workpiece 101″ so produced has specific characteristics according tothe processing stages. For example, properties such as material type,colour and mass depend on the configuration of dispensing station 102-1.The shape of the bottle depends on the configuration of shaping station104-1, conditioning station 108-1 and shaping station 106-1.

Dispensing stations 102-2, 102-3, 102-4 may be configured differentlythan dispensing station 102-1. For example, dispensing stations 102-2,102-3, 102-4 may contain different feedstock materials and/or differentcolours.

Likewise, shaping station 104-1 may be configured differently from theother stations or snapping cell 104 and shaping station 106-1 may beconfigured differently from other stations of shaping cell 106. Forexample, each station of shaping cell 104 may have installed a molddefining a unique preform size and shape. Each station of shaping cell106 may have installed a mold defining a unique bottle size and shape. Apre-shaped workpiece 101′ having a given size, shape and weight may betransformed into any of multiple possible types of finished workpiece101″ (e.g. bottles of different sizes and shapes), depending on theshaping station 106 at which the pre-shaped workpiece is processed.Similarly, a station of shaping cell 106 may be used to form any ofmultiple possible types of finished workpiece 101″, depending on thepre-shaped workpiece 101′ that is used. For example, a larger pre-shapedworkpiece 101′

Stations of conditioning cell 108 may also be configured differently toproduce articles with different characteristics. For example, the finalshape created at a station of shaping cell 106 may be influenced by thetemperature profile of workpiece 101′ at the beginning of shaping. Thatis, higher-temperature portions of workpiece 101′ may be more readilyre-shaped. Accordingly, a station of conditioning cell 108 may beconfigured to a produce a non-uniform temperature distribution in aworkpiece 101′ in order to result in non-uniform stretching, e.g. intoan oblong shape.

Transport subsystem 110 flexibly interconnects stations of process cells102, 104, 106, 108, such that molding system 100 can be rapidlyconfigured to produce parts having varied characteristics. In someembodiments, multiple types of parts having different colours, shapes,sizes, or the like can be produced simultaneously.

FIG. 52 is an overhead plan view of system 100, showing an exampleconfiguration of transport subsystem 110.

As noted, in the depicted example, transport subsystem 110 includes aseries of tracks 144. Tracks 144 are arranged in individual segments144-1, 144-2, 144-3, . . . 144-n. Segments 144-1, 144-2 are shared loopsfor accessing any station of dispensing cell 102, shaping cell 104 andconditioning cell 108, respectively. Other segments are branchesconnecting the shared loops with individual stations or connectingshared loops together. In the depicted embodiment, 16 track segments arepresent, including two shared loops. However, more or fewer tracks maybe present, including more or fewer shared loops, depending on theconfiguration of system 100. For example, the number of stations withineach of process cells 102, 104, 106, 108 and the physical layout of thestations may influence the total number of tracks 144 and the number ofshared loops of tracks 144. In some embodiments, transport subsystem 110may not include any shared loops of tracks 144.

Each of tracks 144 is configured to releasably engage and retaincarriages 125, 129. The carriages may, for example, be coupled to thetracks 144 by rollers which interlock with the tracks 144. Alternative,carriages 125, 129 may be magnetically coupled to tracks 144. In someembodiments, carriages 125, 129 may be mounted to shuttles whichthemselves are coupled to and movable along tracks 144. In someembodiments, such coupling may be electromagnetic or may be achievedusing suitable mechanical fasteners.

Carriages 125, 129 may be moved along tracks 144 by any suitable drivemechanism. In some embodiments, carriages 125, 129 may be coupled to abelt or chain drive carried on tracks 144. In other embodiments,carriages 125, 129 may be moved by electromagnetic drives. For example,the magnetic drive may comprise an array of driving electromagneticinduction coils which can be sequentially activated to lift and move amagnetized vessel 125, 129 along track 144. An array of electromagneticdetection coils may be positioned proximate the array of drivinginduction coils and may be used to detect and track the position of thevessels 125, 129.

As will be apparent from FIG. 52, paths through system 100 may includeone or more of shared track loops 144-1, 144-2 as well as one or moreindividual track segments. For example, a path through dispensingstation 102-1, shaping station 104-1, conditioning station 108-1 andshaping station 106-1 may require carriages 125, 129 to bear a workpiecealong each of track loops 144-1, 144-2 a nd track segments 144-3, 144-7and 144-15.

Transport subsystem 110 is equipped with a control system 1000 fordirecting and tracking the positions of carriages 125, 129. In someembodiments, the position of individual carriages 125, 129 may betracked using a drive mechanism with a position encoder. In otherembodiments, position of carriages 125, 129 may be tracked using amachine vision system, radio frequency tracking or other suitabletechniques.

In some embodiments, a large number of carriages 125, 129 maysimultaneously be carried on tracks 144. Accordingly, control system1000 may maintain a data structure containing position data for eachcarriage 125, 129.

At some locations in transport subsystem 110, carriages 125, 129 may betransferred from one segment of track 144 to another segment of track144. Such transfers may be affected by diverter units (not shown). Forexample, a diverter unit may be provided at each junction between ashared track loop 144-1, 144-2 with another track segment. Diverterunits, under control 61 control system 1000 are operable to selectivelyengage a carriage 125, 129 remove the carriage from a first segment oftrack 144, move the carriage 125, 129 to a second segment of track 144,and disengage from the carriage once the carriage is coupled to thesecond segment of track 144. Diverter units may be activated based onmeasured position of carriages 125, 129 on track 144.

Thus, by operation of diverter units under control of control system1000, each part produced by molding system 100 may follow a specificselectable path through the system 100.

Molding system 100 can therefore be configured to contemporaneouslyproduce one or more parts of common or multiple types, in substantiallyany proportion. For example, parts may be produced in a lot size assmall as one unit, i.e. a single part having a particular set ofcharacteristics.

For example, in a specific configuration, dispensing cell 102 mayinclude multiple stations with the same materials, while each station ofshaping cells 104, 106 includes a mold of a unique shape. By coordinatedoperation of diverter units, any given dose of feedstock material may bedirected through a sequence of process stations to produce a specifictype of article, while a different arrangement of operation of diverterunits would direct a dose of feedstock material through a differentsequence of process stations, to produce a different type of part.

Transport subsystem 110 and the stations of process cells 102, 104, 106,108 collectively define a large number of paths through molding system100. For instance, a unique path corresponds to and is defined by eachunique combination of a dispensing station; a shaping station of cell104; a conditioning station of cell 108 and a shaping station of cell106. In addition, in some embodiments, one or more of cells 104, 106,108 may be bypassed. For example, in some cases it may be possible toimmediately transport a workpiece from shaping cell 104 to shaper cell106, without an intermediate conditioning step. This may be possible,for example, when the workpiece temperature following the first shapingoperation is relatively high, and when the workpiece can be transportedrelatively quickly to a station of shaping cell 106, such that it doesnot lose significant heat, or when the shaping processes and molds aredesigned such that the temperature profile of a workpiece exiting astation of shaping cell 104 is ideal for a process to be performed atshaping cell 106.

Alternatively or additionally, in some embodiments, additional processcells may be present and may be included in some paths through moldingsystem 100. For example, one or more of a bottle or preform coatingcell, labelling cell, filling cell, capping cell or inspection cell maybe present.

An inspection cell (not shown) may include a detection device positionedproximate part of transport subsystem 110, for observation of aworkpiece such as a molded preform or a finished molded article as it isconveyed past the detection device. The detection device generallycomprises a camera and an evaluation unit. Images of the workpiece areproduced by the camera, the images being compared with setpoint valuesof a fault-free workpiece using image processing methods, in order todetermine whether defects are present. The inspection cell may includefurther means for diverting molded articles that are considereddefective.

FIGS. 53 and 54 are plan and side views of an injection molding system6000 made in accordance with another embodiment of the subject system.Parts of system 6000 which are the same as parts of system 100 are givenlike reference numerals.

In overview, molten molding material is transferred to individualvessels 124, which are then conveyed to subsequent process cells along atrack 6110. The vessels are carried by independently controllablecarriages and progress serially along an outgoing line of the track. Avessel may be stopped at a molten molding material dispensing cell 102where a dose of molten molding material is dispensed from a moltenmolding material dispenser (which may also be referred to as a moltenmolding material station) 102-1, 102-2—which, in the illustratedembodiment is an extruder 112—into the vessel. The vessel is thenadvanced further along the track to a preform molding cell 6104 wherethe molten molding material is dispensed from the vessel to a preformmolder (preform molding station) 6104-1, 6104-2, 6104-3, 6104-4, 6104-5,6104-6. The vessel is then shunted to a return line. Preforms 101′molded at a preform molding cell are transferred to carriages on thereturn line. The return line runs past conditioning cell 108 and blowmolding cell 106 where preforms on the return line are transferred toconditioners 108-1, 108-2 and blow molders 106-1, 106-2 and blow moldedinto articles. At the end of the return line, vessels are shunted backto the outgoing line, optionally after having been first parked at abuffering and cleaning cell 6530.

A controller monitors the location of each carriage, vessel, and preformand controls movement, so that the right vessel is filled with the rightmolten molding material, this molten molding material is dispensed tothe right preform molder, and the preform formed at this molder istransferred to the right blow molder.

With this system, a variety of different blow molded articles can bemade by providing differing preform molders and blow molders at cellsalong the track, and filling vessels with different doses and differentcompositions of molten molding material suited for ones of the preformand blow molders.

The track 6110 of injection molding system 6000 is made up of repeatingsegments. With reference to FIGS. 55A and 55C, each track segment 6540has an array of electromagnets 6542 extending along its length. Eachtrack segment also has a scale 6543 and an encoder output sensor 6544extending along its length. The controller provides control voltages tothe electromagnets of the track segments and is connected to the encoderoutput sensor.

to Carriages ride on the track. With reference to FIGS. 55B and 55C,each carriage 6125, 6129 is supported on the track by rollers 6546 thatride on upper and lower track surfaces which prevent a carriage fromlifting off the track. Each carriage has a series of permanent magnets6548 and a position encoder flag 6550 that is responsive to the scalecarried by the track to output position pulses sensed by the encoderoutput sensor of the track. With this arrangement, the controllerremains aware of the current location, identity, and velocity of eachcarriage on the track and can independently move each carriage in eitherdirection on the track by application of suitable control voltages tothe electromagnets of the track.

Track 6110 and carriages 6125, 6129 may be those manufactured byBeckhoff Automation GmbH & Co. KG under the trademark XTS.

Returning to FIG. 54, the track of injection molding system 6000 has anoutgoing line 61100, a parallel return line 6110 r disposed directlyabove the outgoing line, a spur line 6110 sp stood off from the left endof the return line, a left side shunt line 61101 s that may be shiftedfrom a lower position where it extends the outgoing line to a raisedposition where it extends the return line and joins the return line tothe spur line, and a right side shunt line 611Ors that may be shiftedfrom a lower position where it extends the outgoing line to a raisedposition where it extends the return line.

Referring to FIG. 56 along with FIGS. 55A and 55B, an upwardly extendingarm 6564 is attached to each carriage 6125 and an upwardly extending arm6569 is attached to each carriage 6129. The arm 6564 of carriages 6125has a pair of horizontally projecting flanges 6566, each of whichterminates in a concave arcuate tip 6568. The upwardly extending arm6569 of carriages 6129 has a horizontally projecting flange 6576 whichterminates in a concave arcuate tip (not shown). The arms 6564, 6569alternate in orientation from one carriage to the next such that acarriage 6125 a on the outgoing line 6110 o with rightwardly projectingflanges 6564 a trans a carriage 6125 b on the outgoing line 6110 o withan arm having leftwardly projecting flanges 6564 b. (On the return line6110 r this is reversed: a carriage 6125 a on the return line 6110 rwith rightwardly projecting flanges 6564 a leads a carriage 6125 b withan arm having leftwardly projecting flanges 6564 b.) With thisarrangement, carriages can be grouped into pairs of adjacent carriageswhich have complementary features, namely flanges that are opposed toone another. The carriages 6125, 6129 with different lengths of arms arearranged such that, on the outgoing line 6110 o, a pair of carriages6129 a, 6129 b with longer length arms 6569 a, 6569 b leads a pair ofcarriages 6125 a, 6125 b with shorter length arms 6564 a, 6564 b. (Onthe return line 6110 r this is reversed: a pair of carriages 6125 a,6125 b with shorter length arms leads a pair of carriages 6129 a, 6129 bwith longer length arms.)

The flanges 6566 of the shorter arms are configured so that an opposedpair of such flanges, when moved toward each other, will fit within theannular notches 1255, 1256 (FIG. 7A) of a vessel 124 and trap (pinch)the vessel between the pair of flanges. Moreover, the length of theshorter arms is such that, with a vessel trapped between a pair offlanges, the vessel clears the base of the carriages 6125 below thevessel. The flanges of the longer arms are configured so that an opposedpair of such flanges, when moved toward each other, will extend around apreform workpiece 101′ (FIGS.29J and 68) below the lip 6570 (FIG. 60) ofthe preform such that the lip 6570 of the preform will be supported onthe opposed flanges.

Returning to FIGS. 53 and 54, the injection molding system 6000 isdivided into a number of cells. Cells that are used along the outgoingline 6110 o are, from left to right, a left side shunting cell 6620, are-ordering cell 6630, a molten molding material dispensing cell 102, apreform molding cell 6104 and a right side shunting cell 6640. Cellsthat are used along the return line are, from right to left, the rightside shunting cell 6640, the preform molding cell 6104, conditioning andblow molding cell 106/108, the left side shunting cell 6620, and abuffering and cleaning cell 6530.

Each shunting cell 6620, 6640 comprises a shunt line and an elevator towhich the shunt line is mounted. Returning to FIG. 56, the right sideshunt line 611Ors is attached for sliding movement on vertical pillar6660. The vertical pillar is essentially a track segment with a seriesof electromagnets, like track segment 6540. Magnets (not shown) aremounted to the shunt line 6110 rs such that the shunt line is a carriageriding on the pillar. The controller is connected to a control input ofthe pillar. With this arrangement, the pillar acts as an elevator 6662for the shunt line 6110 r s to move the shunt line between the loweroutgoing line 6110 o and the upper return line 6110 r. It will beapparent that when the right side shunt line is vertically aligned withthe outgoing line, the shunt line abuts the right side end of theoutgoing line 6110 o and effectively lengthens the outgoing line.Similarly, when the shunt line is vertically aligned with the returnline 6110 r, the shunt line abuts the right side end of the return lineand extends the return line. The left side shunt line is configured inlike manner, however, additionally, when the left side shunt line isaligned with the return line, it also abuts the end of the spur line6110 sp (FIG. 54) so as to join the return line 6110 r to the spur line.

Re-ordering cell 6630 has one or more re-ordering devices 6632. Turningto FIG. 57 which illustrates one re-ordering device 6632, the device hasa rail 6670 extending transversely of the outgoing line 6110 o, which isconfigured as the primary part of a linear actuator, and a carriage 6672slidably mounted on the rail, which carriage is the secondary part ofthe linear actuator. A rotary servo motor is mounted to the carriage anda turntable 6676 (which is a gearbox) is mounted to the rotor (notshown) of the servo motor. Four outwardly directed grippers 6680-1,6680-2, 6680-3, 6680-4 are mounted to, and equally spaced about, theturntable. The grippers may be servo driven or spring biased closed withan air circuit to open. The controller provides a control input to thelinear actuator and to the rotary servo motor, as well as to thegrippers.

As seen in FIG. 53, the two molten molding material dispensers 102-1,102-2 are positioned one on each side of the outgoing line and staggeredalong the line. A hand-off device 6730 is associated with each moltenmolding material dispenser. Turning to FIG. 58, the hand-off device 6730has a rail 6770 extending transversely of the outgoing line 6110 o,which is the primary part of a linear actuator, and a carriage 6772slidably mounted on the rail, which carriage is the secondary part ofthe linear actuator. The stator (not shown) of a rotary servo motor ismounted to the carriage and a turntable 6776 is mounted to the rotor(not shown) of the servo motor. Two pairs of outwardly directed grippers6780-1, 6780-2—closed by a spring bias and opened with an air circuit,or servo controlled—are mounted to the turntable opposite one another.The controller provides a control input to the linear actuator and tothe servo motor, as well as to the grippers.

The preform molding cell 6104 has preform molders 6104-1, 6104-2,6104-3, 6104-4, 6104-5, and 6104-6 staggered along either side of theoutgoing line. The preform molders are similar to preform molders 104-1,104-2, 104-3, 104-4, 104-5, 104-6, 104-7, 104-8, except as todifferences described hereinafter. Referencing FIG. 59, similar to thepreform molders of cell 104, an actuator assembly has a verticallymoveable nest 2044 with a semi-annular slot (seen in FIG. 32) that thebase of a vessel 124 can slide into so as to be retained by the nest. Ahand-off device 6830 having two pairs of outwardly directed grippers6840-1, 6840-2, like the hand-off device 6730, is associated with eachmolten molding material dispenser and is mounted between each preformmolder and the outgoing line 6110 o for transferring a vessel to andfrom the nest 2044 of a preform molder.

With the preform molders 104, a carriage 129 (FIG. 341) riding on asecond track 144 that extends below the preform molder 104 is positionedbelow the preform mold 200 prior to the inner mold core 3112 (FIGS. 18B)being moved upwardly to a short extent to break a seal between thepreform and the mold core 190. The carriage 129 has a nest shaped toreceive the preform and suction may be applied to draw the preform intothe nest. In contrast, in injection molding system 6000, as shown inFIG. 59, the transfer device is a robot arm 6850 which is mounted besidethe mold 200 of each preform molder 6104. With injection molding system6000, prior to breaking the seal between the preform and mold core, therobot arm is manipulated so that its end effector grips the preform.

With reference to FIG. 60 along with FIG. 59, robot arm 6850 has a fixedtrunk 6852 supporting the stator of a first servo motor 6854. An upperrobot arm 6856 is mounted at a first end to the rotor 6858 of the firstservo motor. The second end of the upper robot arm supports the statorof a second servo motor 6860 and one end of a lower robot arm 6862 ismounted to the rotor 6864 of the second servo motor 6860. The second endof the lower robot arm 6862 has a distal rotatable pulley 6870, and theend effector 6872 is mounted to the shaft of the distal pulley so as toproject transversely from the shaft. The end effector has a pair ofservo controlled grippers 6874 a, 6874 b. A base pulley 6876 is fixed tothe trunk 6852 such that it does not rotate. A double width medialpulley 6878 is rotatably mounted to the robot arm coincident with therotational axis of the rotor 6864 of the second servo motor 6860. Allthree pulleys 6870, 6876, 6878 have the same radius A coupling belt 6880extends around the base pulley 6876 and medial pulley 6878. A secondcoupling belt 6882 extends around the medial pulley and the distalpulley 6870. The controller controls the servo motors of the robot armto position the end effector. In this regard, as will be appreciated bythose skilled in the art, with the end effector initially projectinghorizontally, the end effector will maintain its horizontal orientationas the lower and upper arms are rotated by the servo motors 6850, 6860due to the operation of the coupling belts 6880 and 6882. The controlleralso controls the grippers of the end effector.

Referring to FIG. 59 along with FIG. 60, with this arrangement, afterthe robot arm is moved into position with its grippers 6874 a, 6874 bgripping a preform 101′ and the seal is broken between the preform andmold core 3112 (FIG. 18B), the robot arm is controlled to first lowerthe preform 101′ so that it descends to clear the mold core. (It will beappreciates mat inc spent vessel is lust. removed from below the mold200 so that it will not interfere with this operation.) After thepreform clears the mold core, it is translated to the return line 6110 rand, specifically, to a position between a spaced pair of carriages 6129a, 6129 b with opposed longer length arms 6569, with the lip 6570 of thepreform above the horizontally projecting flanges 6576 (FIG. 56) of arms6569. These carriages are then moved together to trap the preformbetween the opposed arms 6569. The end effector of the robot arm thenreleases the preform and withdraws. The preform is then retained by theopposed arms 6569 with its lip 6570 resting on the flanges 6576 of theopposed arms 6569 of the pair of carriages 6129 a, 6129 b.

Returning to FIGS. 53 and 54, a blow molder 106-1, 106-2, with itsassociated conditioner 108-1, 108-2, lies on either side of the returnline 6110 r. A track 6996 perpendicular to main track 6110 is associatedwith each blow molder/conditioner to transfer a preform from the returnline to a particular blow molder/conditioner. Alternatively, thetransfer device may be the aforedescribed mandrel 408 (FIG. 34), or arobot arm similar to the robot arm illustrated in FIGS. 59 and 60.

Details of track 6996 are depicted in FIGS. 61-63. FIGS. 61 and 62depict top and side views, respectively, of blow molder 106-1 andassociated conditioner 108-1, and the transfer device. FIGS. 64A and 71Bdepict isometric and side views, respectively, of carriages mounted ontrack 6996.

As shown in FIG. 61, track 6996 extends away from main track 6110 andspans across block molder 106-1 and conditioner 108-1. Track 6996 issubstantially identical to main track 6110, except that track 6996 isinclined at an angle to the vertical. Likewise, pairs of carriages 6129′are mounted to track 6996. Carriages 6129′ are substantially identicalto carriages 6129 except that carriages 6129′ have arms 6569′ whichextend horizontally, at an angle to track 6996.

Pairs of carriages 6129′ are movable towards one another to grip apreform between arms 6569′. Specifically, a pair of carriages 6129′ ontrack 6996 is positioned above a pair of carriages 6129 on main track6110. Carriages 6129′ grip a preform held by carriages 6129, and thecarriages 6129 are then moved to release the preform. Accordingly, thepreform is transferred from carriages 6129 to carriages 6129′. Arms6569′ of carriages 6129′ may grip the preform above flanges 6576 ofcarriages 6129, proximate the top edge of the preform.

After picking up the preform, carriages 6129′ are moved along track 6996to position the preform above conditioner 108-1. A mandrel then engagesthe preform, and carriages 6129′ move apart to release the preform. Themandrel inserts the preform into conditioner 108-1 for treatment andsubsequently withdraws the preform to a position proximate carriages6129 after treatment is completed. The carriages 6129′ then movetogether to again grip the preform and are conveyed along track 6996 toa position aligned with blow molder 106-1.

Specifically, with platens 196 of blow molder 106-1 withdrawn from oneanother, such that mold 500 is opened, carriages 6129′ move the preformto a position between the molds. The height of arms 6569′ is selectedsuch that the preform is slightly above a molding position when grippedby the arms.

With carriages 6129′ holding the preform in a position aligned with mold500, platens 196 are moved to their closed (molding) position by clamp8070. Thus, mold 500 is closed around the preform. Carriages 6129′ arethen moved apart, so that the preform drops into position in mold 500.In the depicted embodiment, the preform drops only a small distance,e.g. a few millimetres. In some embodiments, closing of mold 500 mayoccur in two steps. Specifically, the mold may initially be partiallyclosed, leaving a small clearance around the preform so that it can besupported on mold 500 by an annular support ledge near the top of thepreform, but the preform can freely fall into the correct moldingposition, without binding against the mold.

A mandrel is then moved to engage the preform substantially as describedwith reference to FIGS. 51A-51D. A rod is extended into the preform andstretches the preform as pressurized air is injected through the mandrelto stretch the preform into the shape defined by mold 500.

After molding, the preform is permitted to cool. Carriages 6219′ arethen moved together to again grip the finished molded article (e.g. abottle). When gripping the finished article in mold 500, arms 6596′ gripat a location slightly higher than when they grip the preform atconditioner 108-1. The height difference corresponds to the distance thepreform is dropped subsequent to closing of mold 500.

Carriages 6129′ then move the completed article away from blow molder106-1, where it may be removed for further processing such as labelling.

After removal of the completed article, carriages 6129′ are returnedalong track 6996 to a position for gripping a new preform from maintrack 6110.

The buffering and cleaning cell 6530 comprises spur line 6110sp with anenclosure 6890 containing vessel cleaners (not shown).

The right side shunting cell 6640 comprises the right side shunt line6110 rs and the elevator 6662 to which the right side shunt line ismounted.

A reader 6894 is positioned along the track downstream of there-ordering cell 6630 to read an identifier of passing vessels 124.

Turning to FIG. 64, the controller 6900 has a control input to theelectromagnets 6542 of each track segment, the elevator 6662 of eachshunt line, each re-ordering device 6632, each hand-off device 6730,6830 and each robot arm 6850, and each transfer track 6996. Thecontroller receives an input from the encoder flag 6550 of each carriageand from the vessel identification reader 6894. As illustrated, thecontroller also has a control input to each molten molding materialdispenser of molding material dispensing cell 102, each preform molderof preform molding cell 6104, each conditioner of cell 108 and each blowmolder of cell 106, and the buffering and cleaning cell 6890.Alternatively, some of these devices may have independent controls. Forexample, a preform molder could have a microswitch that is triggeredwhen a hand-off device 6830, under control of the controller, loads avessel into its nest which causes the preform molder to cycle throughits molding operation, and a second microswitch which is triggered whenthe controller positions a robot arm 6850 to receive a molded preform inorder to release the molded preform.

To prepare injection molding system 6000 for operation, feedstock isprovided to the molten molding material dispensers of cell 102. Thecomposition of the feedstock provided to each molten molding materialdispenser may differ in material or colour or both. Thus, by way of anexample embodiment, one molten molding material dispenser holds blue(pellets) feedstock and the second molten molding material dispenserholds green (pellets) feedstock. The type of feedstock provided to eachdispenser is uploaded to the controller.

Given green and blue feedstock, the vessels 124 are divided into firstvessels which are dedicated to holding blue molten moldingmaterial—referred to hereinafter as “blue vessels” for simplicity—andsecond vessels which are dedicated to holding green molten moldingmaterial—referred to hereinafter as “green vessels”. The vessels areorganized in this fashion as, even after cleaning, a vessel will retainsome molten molding material residue. Thus, using only one type ofmolten molding material in a vessel avoids cross-contamination. Eachvessel is marked with an identifier and the identifier on a vessel isread by reader 6894 so that the controller 6900 becomes aware of whichvessels are blue vessels and which vessels are green vessels and canthereafter track the location of each vessel to maintain this awareness.A suitable identifier that may be used is an annular strip code, i.e., apattern of strips that encircle the vessel which may be visually read.An annular strip code has the advantage that it may be read no matterwhat the rotational orientation of the vessel about its longitudinalaxis. In an alternate embodiment, the information as to which carriagepairs and which grippers hold blue vessels and which hold green prior tostart-up is input to the controller and the controller thereafter tracksthe location of each vessel so as to maintain awareness of which vesselis which. However, it is generally preferred to mark each vessel with anidentifier to avoid problems that could otherwise result should anyvessels be manually swapped out or switched during a shut down withoutinforming the controller.

Continuing with the example, the carriages on the track are organized asgangs 6880 (FIG. 56) of four carriages each. On the outgoing line 6110o, the leading pair of carriages 6129 a, 6129 b of each gang 6880 hasopposed longer arms 6596 a, 6596 b and the trailing pair of carriages6125 a, 6125 b has opposed shorter arms 6564 a, 6564 b. (On the returnline 6110 r, it is the pair of carriages with shorter arms that is theleading pair of carriages in a gang.) At start-up, each trailing pair ofcarriages on the outgoing line may hold an empty blue vessel or an emptygreen vessel.

The controller 6900 may receive a product order, say fifty blue bottlesand twenty-five green bottles. Given this, two of the four grippers ofeach re-ordering device may be loaded with blue vessels and one grippermay be loaded with a green vessel, leaving the fourth gripper of eachdevice free: if the system is not configured so that the controller canidentify these vessels, this information is fed to the controller.

The controller may (rapidly) advance the gangs of carriages along thetrack until a gang 6880 of carriages holding a blue vessel is presentedat a molten molding material dispenser holding blue molten moldingmaterial feedstock. In this regard, if there happened to be anuninterrupted series of green vessels upstream of the molten moldingmaterial dispensing cell, the controller may use the re-ordering cell6630 upstream of the molten molding material dispensing cell to swap outgreen vessels from the outgoing line 6110 o and insert blue vessels intheir place. More specifically, the next carriage gang with a greenvessel can be advanced by the controller to a re-ordering device 6632 ofthe re-ordering cell 6630 where it is halted, the turntable 6676 of are-ordering device 6632 operated to direct the empty grippers 6680-1 ofthe re-ordering device toward the outgoing line, and then the turntableadvanced. If the grippers are spring biased, the turntable is advanceduntil the biased empty grippers are first deflected by, and then snaparound, the green vessel. The opposed arms of the leading carriage pair6125 a, 6125 b of the gang which trap the green vessel absorb thereaction force as the empty grippers or the re-ordering device aredeflected by the vessel. With the grippers holding the green vessel, thecontroller then separates the leading pair of carriages so that thegreen vessel is released from the outgoing line. The turntable is thenretracted, turned to present grippers holding a blue vessel toward theoutgoing line, and advanced again to position the blue vessel betweenthe opposed open arms of the leading pair of carriages of the carriagegang. The controller then brings the leading carriage pair back togetherto close the open arms of this pair in order to trap the blue vessel.The grippers are then opened (with an air circuit or under servocontrol) to release the blue vessel, and the turntable is retracted. Thecarriage gang, now holding a blue vessel, may then be advanced to themolten molding material dispensing cell.

It will be apparent that, after this swap, the re-ordering cell 6630continues to have one set of empty grippers but now holds two greenvessels and one blue vessel.

Referencing FIG. 58 and assuming dispenser 102-2 holds blue feedstock,if an empty blue vessel 124-1 is advanced to molten molding materialdispenser 102-2, the controller can operate the carriages 6125 a, 6125 band hand-off device 6730 to transfer the vessel 124-1 to grippers6780-1. More specifically, with the blue vessel halted under at themolten molding material dispenser 102-2, empty grippers 6780-1 of thehand-off device associated with the dispenser are advanced toward theempty blue vessel 124-1 and brought into engagement with the vessel. Thepair of carriages 6125 a, 6125 b trapping the vessel is then separatedto release the vessel. Since the grippers 6780-2 of the hand-off devicehold a blue vessel 124-2 that would have been previously filled atdispenser 102-2, the hand-off device rotates to deliver this previouslyfilled blue vessel 124-2 between the pair of carriages 6125 a, 6125 band these carriages are advanced toward each other to trap this vessel124-2 between them. The grippers 6780-2 are then opened and the hand-offdevice retracted to present the vessel 124-1 held by grippers 6780-1 atthe outlet of the molten molding material dispenser. The retraction ofthe hand-off device also frees the pair of carriages 6125 a, 6125 b withvessel 124-2 to progress along the track. With vessel 124-1 at theoutlet of the molten molding material dispenser 102-2, blue moltenmolding material is dispensed to this vessel 124-1, as aforedescribed inconjunction with the embodiment of FIGS. 8A-8D. In this regard, the doseof material received by a vessel at the molten molding materialdispenser is a dose sufficient to make a single preform, which dose mayor may not fill the vessel. Filled blue vessel 124-1 is then ready to bepicked up by a subsequent pair of carriages arriving on the track. Notethat if grippers 6780-2 did not hold a vessel on the arrival of vessel124-1, the pair of separated carriages 6125 a, 6125 b may be paused inplace at dispenser 102-2 until blue vessel 124-1 is filled and returnedto the pair of grippers.

The filled blue vessel returned to the pair of carriages 6125 a, 6125 bat the dispenser is advanced along the track to the preform molding cell6104. In this regard, specific preform molders may be dedicated formolding blue preforms if there is a risk of a residue of blue moltenmolding material remaining in the preform molder mold 200. Thecontroller preferentially chooses a “blue” preform molder further towardthe right end of the outgoing line 6110 o in order to leave open otherpreform molders between the chosen preform molder and the molten moldingmaterial dispensing cell 102 so that while carriages are paused at thechosen preform molder, they do not block vessels from being advanced tothese other preform molders.

Referencing FIG. 59, assuming the chosen preform molder for a greenvessel 124-3 is preform molder 6104-6, the vessel is advanced by thecarriage gang holding it to this preform molder, engaged by grippers6840-1 of hand-off device 6830, and released by carriages 6125-a, 6125 bof the carriage gang. A previously emptied green vessel held by grippers6840-2 may then be returned to the carriage gang so that the gang isfreed to advance further along the track 61100. The hand-off device thentransfers vessel 124-3 to the nest 2044 of the preform molder. Thevessel positioning actuator is then extended vertically to urge thevessel into abutment with the mold 200 (FIG. 12A), with gate orifice 136of vessel 124 aligned with mold inlet gate 202 of mold 200. The moltenmolding material in the green vessel may then be injected into the mold200—by operation of piston 182 (FIG. 6B) of the vessel asaforedescribed—and the spent green vessel is then ready to be returnedto the outgoing line 6110 o when a next carriage gang arrives at thepreform molder 6104-6.

A carriage gang leaving the preform molding cell is advanced to theright side shunting cell where the elevator 6662 moves the shunt line6110 rs up into engagement with the return line 6110 r. The elevatedcarriage gang then moves back toward the preform molding cell 6104. Oncethis carriage gang leaves the shunt line 6110 r, the shunt line is againreturned to the outgoing line 6110 o.

A carriage gang 6880 arriving on the return line 6110 r with a spentblue vessel may be moved to the preform molder, e.g., preform molder6104-6, that will next have a completed preform 101′, regardless ofwhether the preform is green or blue. At this preform molder, the pairof carriages 6129 a, 6129 b with the longer arms 6569 a, 6569 b (whichis now the trailing pair of carriages of the gang) is separated whilethe robot arm 6850 moves a preform 101′ released from the preform mold200 to a position in between the arms of the separated carriages. Thecarriages 6129 a, 6129 b of the pair are then brought together to trapthe preform between them and the robot end effector 6872 is withdrawn torelease the preform from the robot arm.

The carriage gang may then advance with the preform 101′ to theconditioning and blow molding cell 106/108 where the preform is removedfrom the carriage gang by a transfer device. More specifically, thetransfer device engages the preform, subsequent to which the pair ofcarriages trapping the preform is separated to release the preform. Thetransfer device then inserts the preform into the heating chamber 404 ofa conditioner, say conditioner 108-1. After heating, the transfer devicewithdraws the preform from the heating chamber past a thermal monitor406. If the preform is properly conditioned, the transfer device thenmoves the conditioned preform to blow molder 106-1 and inserts thepreform into the mold 500 of the blow molder. The transfer device thenreleases the conditioned preform and the preform is engaged by themolding head 504 of a mandrel 506, whereupon the preform is blown into abottle as aforedescribed. Where each blow molder blows a bottle ofidentical shape, the preform can be transferred to any of the blowmolders. However, if the bottles blown by different blow molders are ofdifferent shapes, then the preform must be transferred to a blow molderwhich is suited to blowing a bottle from that preform.

After the preform is transferred from the carriage gang 6880, thecarriage gang is further advanced to the buffering and cleaning cell6890 where the empty vessel carried by the gang is optionally cleaned.The controller could then immediately return the carriage gang to theleft side shunt line 61101 s or, alternatively, hold the carriage gangin the buffering and cleaning cell for future use. When the carriagegang is returned to the shunt line 61101 s, the shunt line descends toreturn the carriage gang to the outgoing line 6110 o, and when thecarriage gang is advanced beyond the left side shunt line, the left sideshunt line 61101 s again returns to the return line 6110 r.

It will be apparent from the foregoing that carriage gangs 6880circulate on the track, moving to the right along the outgoing line61100, then being elevated to the return line 6110 r where they move tothe left and, when they reach the left hand end of the upper track, maybe offloaded to the buffering and cleaning cell 6530 or returned to theoutgoing line. With this operation, it will be apparent that the vessels124 are maintained upright throughout their travels. This helps ensuremolten molding material does not leak from the vessels while movingthrough the system. It will also be apparent from the foregoing thatcarriage gangs riding on the outgoing line may hold a vessel but do nothold a preform 101′, and carriage gangs riding on the return line mayhold a vessel, and, in addition, may also hold a preform.

From the foregoing, it will be apparent that the controller has logic tocontrol the carriages 6125, 6129, logic to control the vessels 124, andlogic to control the preforms 101′. The carriage control is enabled bythe encoder flag 6550 on each carriage that is monitored by thecontroller 6900. This allows the controller to track the location ofeach carriage and control its movement as desired. The vessel control isenabled either by the controller being provided with the initiallocation and designation of each vessel (e.g., a blue vessel) or by eachvessel being marked with an identifier that is input to the controllerfrom a reader at one or more locations in the system and the controllerstoring the designation of each marked vessel. The preform control isenabled by the controller storing which preform molders are associatedwith which blow molders, and by the controller tracking carriage gangsthat are loaded with a particular preform so as to offload theparticular preform held by the carriage gang at the appropriate blowmolder.

The example operation described assumed the system was run withfeedstock of two different colours. The system could also be run withfeedstock more than two colours, for example, five different colours. Inthis instance, the system may be modified to provide five molten moldingmaterial dispensers, one for each colour of feedstock, and at least twoseparate re-ordering devices in the re-ordering cell, such that at leastone vessel for each of the five colours may be held at the re-orderingcell while ensuring at least one of the two re-ordering devices has anempty set of grippers. The system could also be run with multipledifferent types of feedstock. In general, the system could be run withany feedstock that forms a flowable molten material. For example, thefeedstock could be a thermoplastic, a thermoset plastic resin, or aglass. Giving a specific example, in a system with three molten moldingmaterial dispensers, one could hold high density polyethylene (HDPE),one polypropylene (PP), and one polyethylene terephthalate (PET).

The system could be modified to have preform molders and blow molderswith different sized molds which form blow molded articles of differentsizes. In this instance, preforms molded at a particular preform molderare fed to a particular blow molder adapted to blow mold the particularpreform. Thus, the controller must track the carriage gang 6880 whichreceives a preform 101′ to ensure the preform reaches the correct blowmolder. Further, it may be that less molten molding material is neededto form a smaller molded article. In this situation, vessels 124supplying the preform molder for the articles requiring less moltenmolding material are not filled to capacity at a molten molding materialdispenser but are instead filled a metered amount reflective of theneeded volume of molten molding material for the smaller blow moldedarticles.

While the example embodiment shows a re-ordering cell 6630 with twore-ordering devices, each having one set of empty grippers, optionally are-ordering device may have several sets of empty grippers and there maybe multiple re-ordering devices so that several pairs of grippers may beempty and several may hold vessels, so that a selected pair of grippers(with or without a vessel) may be advanced toward the track.

Optionally, heaters may be added to system 6000 to warm vessels 124 atperiodic intervals in order to make up for heat loss in the vesselsduring vessel transit along the track. For example, heaters may belocated upstream of the dispensing cell 102 so that vessels are warmedprior to melt being dispensed to them. FIGS. 65 and 66 illustrate suchan arrangement where a heating system is associated with a re-orderingcell 6330′ upstream of the dispensing cell. Turning to these figures,each re-ordering device 6632′ is identical to the re-ordering device6632 of FIG. 57 except that each device 6632′ has two pairs of grippers6680-1 and 6680-2 rather than four pairs of grippers. Two heaters 6690are positioned beside each device 6632′. Each heater has a pair ofreciprocal prongs 6692 that may be extended by an air cylinder (notshown) inside the housing. A power supply (not shown) inside the housingselectively supplies AC power to the prongs. To adapt the vessels foruse with the heaters 6690, the vessels 124′ are provided with a pair ofconductive bands 6694. The heating system also has a temperature sensor6696 associated with each heater 6690. The temperature sensor is aninfrared sensor that emits an infrared beam. The heating system ispositioned such that a re-ordering device 6632′, when retracted awayfrom the outgoing line 61100 of the track, may be rotated about itscarriage 6672 to a parked position whereat a vessel 124′ in each of thetwo pair of grippers 6680-1, 6680-2 of the device 6632′ is adjacent aheater 6690 and in the path of a beam emitted from the associatedtemperature sensor 6696. The controller is operatively connected to theheaters and temperature sensors. Based on the temperature of a vessel124′detected by a temperature sensor, the associated heater may beselectively energized by the controller to heat the vessel to a desiredtemperature as measured by the temperature sensor. More specifically,the prongs of the heater are extended into contact with the conductivebands of the vessel and AC power is applied to the prongs until thetemperature sensor measures the target temperature. The heater may thenbe de-energised and the prongs retracted. The vessel, warmed to thetarget temperature, may then be transferred to the outgoing line of thetrack.

Given the provision of a heater and temperature sensor for each of thetwo pairs of grippers 6680-1, 6680-2 of a re-ordering device 6632′, iftwo vessels are held by the re-ordering device (and another upstreamre-ordering device has at least one pair of free grippers to take avessel off the line or some upstream carriage gangs on the outgoing lineare not carrying vessels), both vessels may be simultaneously heated.This is useful if both vessels are currently needed on the outgoing line6110 o. On the other hand, if only one of the vessels were needed on theoutgoing line, only that vessel would be heated.

In a modification, only one heater and associated temperature sensor isassociates with each re-ordering device.

While in the example embodiment the buffering and cleaning cell 6530 islocated at the left hand end of the track, optionally this cell couldinstead be located elsewhere. In this instance, the buffering andcleaning cell may not include a spur line, but instead could includeanother arrangement to transfer vessels from the track to the enclosure6890 containing vessel cleaners. For example, a vessel cleaningenclosure could be located at the re-ordering cell 6630 and the grippersof the re-ordering cell could selectively transfer vessels from thetrack to the vessel cleaning enclosure 6890. Alternatively, thebuffering cell could be located elsewhere along the track and a robotarm, similar to robot arm 6850, could be provided in place of the spurline to transfer vessels from the track to the vessel cleaningenclosure.

Each carriage gang may hold a vessel as the carriage gang travels alongthe track. Alternatively, some of the carriage gangs may travel all orportions of the track without holding a vessel.

While the carriages have been described as travelling in gangs of four,alternatively, the carriages could travel in gangs of two, with one typeof gang designed for holding vessels and a second type of gang designedfor holding preforms. As a further option, carriages could travel ingangs of three where the middle carriage has two arms—a right facing armfor co-operating with a left facing arm of the leading carriage and aleft facing arm for co-operating with a right facing arm of the trailingcarriage. While the carriages 6125 are shown as having a pair ofhorizontally projecting flanges 6566, in another embodiment, they mayhave a single horizontally projecting flange, or multiple horizontallyprojecting flanges.

As another option, each carriage could support a set of grippers openingalong the length of the track, such as the biased tongs 1252 of carriage125 of FIG. 7A, to hold vessels. With this option, it will be apparent avessel is held by a single carriage. With this option, each carriage canalso be provided with a further set of spring biased tongs projecting inthe opposite direction to that of the first set of tongs with thefurther set of spring biased tongs being adapted to hold preforms.

Other track configurations are possible. For example, the function ofthe upper and lower lines could be reversed such that molten moldingmaterial is dispensed to vessels on the upper track and preforms aremoved to the conditioning and blow molding cell along a lower track.Also, track and carriage systems other than the XTS system of Beckhoffmay be used to provide controlled movement of carriages on a track.

It will be apparent from the foregoing that injection molding system6000 may be adapted to form a variety of different sized or shapedbottles by switching in suitable molten molding material dispensers,preform molders and conditioners and blow molders.

While the injection molding system 6000 has been described as firstmolding a preform and subsequently blow molding a bottle from thepreform, the system may also be used without the conditioning and blowmolding cell to produce preforms for blow molding in a differentlocation. Also, the system can be used without the conditioning and blowmolding cell and the molds of the preform molders adapted to moldarticles other than preforms such as, for example, plastic toys. Othermodifications will be apparent to those of skill in the art.

FIG. 67 is a flow chart showing an example method 600 of transportingmolding material.

At block 602, a vessel 124 is positioned at a station of dispensing cell102. The coupling assembly of vessel 124 is aligned to and coupled withthe nozzle assembly 113 of an extruder 112. Orifice 136 is opened andmolding material is dispensed into cavity 134 of vessel 124 throughorifice 136.

After filling of vessel 124 is complete, at block 604, vessel 124 issealed, e.g. by operation of sealing member 140. At block 606, thesealed vessel is moved, e.g., along track 144 of transport subsystem110, to a subsequent processing station. The subsequent station may be,for example, a shaping station.

At block 608, the vessel 124 is aligned with the subsequent processingstation. The vessel is unsealed during such alignment. In someembodiments, alignment causes unsealing of the vessel, e.g. byinteraction of closure assembly 1270 with slot 2084.

At block 610, the vessel 124 is mated to the processing station. Forexample, the coupling assembly of vessel 124 is moved into sealingengagement with mold 200 of a shaping station and orifice 136 is alignedwith the mold gate.

At block 612, piston 182 is actuated to reduce the volume of theinternal cavity 134 of vessel 124, thereby forcing molding material outof vessel 124 and into mold 200.

FIG. 68 is a flow chart showing an example method 700 of producingplastic molded articles.

At block 702, a process path, defined by a sequence of process stations,is selected according to the desired characteristics of an article to beproduced. That is, a dispensing station 102-1, 102-2, . . . 102-n isselected according to the desired material, colour and the like. Shapingand conditioning stations may also be selected, as applicable. In someembodiments, multiple possible process paths may exist for forming aspecific type of article. In such cases, a process path may be chosenbased on one or more criteria such as production time, idle processstations and the like.

At block 704, the selected dispensing station is activated and moltenfeedstock is dispensed from the corresponding extruder 112 into a vessel124 as described above. The dispensed feedstock in its molten form isreferred to as a workpiece 101. The workpiece is transformed at otherstages in the process path. For example, the workpiece may experiencestate changes (e.g. from molten to solid states); shape changes; andcondition changes such as temperature or thermal profile changes.

At block 706, the vessel 124 is conveyed in its carriage 125 along track144 to the next processing station. Diverters of the transport subsystem110 are operated to direct the carriage along track 144 to the selectedshaping station 104-1, 104-2, . . . 104-n. For example, selected ones ofthe diverters may be activated at specific times to move vessel 124 toeach station along the process path. The molten feedstock, i.e.,workpiece 101 is injected into mold 200. The workpiece is shapedaccording to the shape of the mold into a pre-shaped workpiece 101′(e.g. a preform for molding a bottle) as described above.

The pre-shaped workpiece 101′ is removed from the shaping station by acarriage 129. If a conditioning operation is selected, at block 708, thecarriage 129 is conveyed to a conditioning station 108-1, 108-2, . . .108-n. Diverters of the transport subsystem are operated to direct thecarriage 129 to the selected conditioning station. If no conditioningoperation is selected, conditioning cell 108 is bypassed.

If a further shaping operation is selected, at block 710, the pre-shapedworkpiece 101′ is conveyed to the selected shaping station 106-1, 106-2,. . . 106-n. Shaping, e.g. blow molding, is performed as described aboveto transform the pre-shaped workpiece 101′ into a finished workpiece101″.

In some embodiments, additional finishing operations may be performed.For example, labels may be applied to containers, or containers may befilled and closed.

The process repeats as long as there are parts to be produced, or untiloperation of molding system 100 is interrupted, e.g. for changing ormaintenance of components.

In some embodiments, components may be subjected to a cleaning process.For example, vessels 124 may be cleaned after transferring feedstock toa shaping station. Cleaning may, for example, be affected by heating ofvessels to melt and drain feedstock residue, by scraping or othermechanical agitation of feedstock within vessels 124, or by a fluidizedbed bath, pyrolysis, or dry ice blast cleaning. Cleaning may beperformed in a buffering area or in a discrete cleaning area.

During a period in which molding system 100 is operated, processsequences may be varied, such that molding system 100 producesheterogeneous output including molded articles of multiple types. Outputincluding multiple types of molded articles may correspond to one ormore production orders. That is, a first order may call for containersof a first type to be produced in a first quantity, while a second ordermay call for containers of a second type to be produced in a secondquantity. The two orders may be fulfilled concurrently according tosystems and methods described herein. Orders (also referred to as“lots”) may be as small as a single molded article.

In some configurations, molding system 100 is configured so that asingle process path is available to produce a given part type. That is,containers having a given size, shape and material type may be producedby a unique combination of stations in each of dispensing cell 102,shaping cells 104, 106, and conditioning cell 108. In other examples,molding system 100 may be configured such that multiple process pathsare available to produce parts of the same type. For example, a singledispensing station 102 may dispense feedstock of a particular materialtype and colour. That feedstock may be provided to two stations ofshaping cell 104, two stations of conditioner cell 108, and two stationsof shaping cell 106. That is, a single dispensing station may correspondto and feed two parallel sets of pre-shaping, conditioning and finalshaping stations. The ratios of stations of shaping cell 104,conditioning cell 108 and shaping cell 106 need not be 1:1. Rather, theratios may differ based, for example, on the length of time required foreach operation. For example, if an injection molding process at cell 104takes twice as long as a conditioning process at cell 108 or a blowmolding process at cell 106, twice as many stations in cell 106 may beprovided for producing a particular type of part.

As described above, transport subsystem 110 includes a guide, namelytracks 144, along which vessels 124 and workpieces are moved.Alternatively or additionally, other types of guides may be used. Forexample, transport subsystem 110 may include one or more conveyors suchas belt conveyors. Alternatively or additionally, transport subsystem110 may include one or more robotic devices. Such robotic devices mayfor example be multi-axis robots with suitable end effectors, and may beoperable to transfer vessels 124 or workpieces between stations of cells102, 104, 106, 108. In such embodiments, process paths may be defined bystations through which workpieces can be processed.

As described above, stations of dispensing cell 102 dispense doses offeedstock material into vessels 124 to define workpieces. The amount ofmaterial in each dose corresponds to the amount of material in a singlepreform workpiece 101′ and a single final-shape workpiece 101″. In otherembodiments, doses of feedstock dispensed by stations of dispensing cell102 may differ. For example, doses may comprise any multiple of theamount of material in a single preform workpiece 101′ or in a singlefinal-shape workpiece 101″. In such embodiments, feedstock material in asingle vessel 124 may feed multiple injection cycles at a shapingstation to 106. For a vessel 124 containing sufficient feedstock for twopreform workpieces 101′, half of the feedstock may be injected into themold of a shaping station 106-1, 106-2, . . . 106-n in each of twocycles. Alternatively or additionally, one or more shaping stations mayhave a mold 200 with multiple molding cavities, for simultaneouslyproducing multiple preforms. In other embodiments, feedstock doses maybe slightly larger than the amount of material required to mold one ormore parts. In other words, a small surplus of material may be dispensedinto vessels 124, such that residual material remains in the vesselafter transferring to a station of shaping cell 104. The residualmaterial may remain in the vessel for a subsequent filling of thevessel, or may be cleaned from the vessel.

In other embodiments, stations of dispensing cell 102 may dispense dosesof a smaller quantity of material than is required to form a singlepreform workpiece 101′ or final-shape workpiece 101″. For example, avessel 124 may receive doses of different materials from multiplestations of dispensing cell 102, such that the vessel 124 simultaneouslyholds multiple types of materials. The vessel 124 may then betransported to a station of a shaping cell to form a molded workpiece ofcomposite material construction, such as multi-layered construction.

In some embodiments, vessels 124 may be sequentially delivered to astation of a shaping cell 104, 106, such that feedstock doses frommultiple vessels 124 contribute to a single molded article. For example,an article of composite material construction may be formed by injectionof a first material from a first vessel 124 and a second material from asecond vessel 124, prior to molding.

Apparatus and methods disclosed herein may allow for relatively flexiblereconfiguration. Each station of dispensing cell 102, shaping cell 104and shaping cell 106 can be reconfigured by removal and replacement ofcomponents such as an extruder barrel 114 and screw 116, or a mold 200or a mold 500 may be easily removed from a station and replace with adifferent barrel and screw or mold. Stations of conditioning cell 108may be reconfigured by removal and replacement of components, or byadjusting controls based on a desired thermal profile.

In some embodiments, reconfiguration of stations may be done withoutinterrupting operation of system 100. For example, an extruder 112 maybe removed while other stations of dispensing cell 102 continue todispense feedstock. Likewise, a mold 200 or a mold 500 can be removedand replaced during operation of the other cells, and reconfiguration(e.g. physical adjustment of re-programming) of a conditioning statementmay be done while other conditioning stations continue to operate.

Thus, apparatus and methods disclosed herein may provide for flexibilityof production in that the plurality of process paths through dispensingcell 102, shaping cell 104, conditioning cell 108 and shaping cell 106allow for concurrent production of many different types of articles.Moreover, some or all stations of the cells may be changed orreconfigured without interruption of production, which further increasesthe variety of articles that may be produced during a production run.

When introducing elements of the present invention or the embodimentsthereof, the articles “a,” “an,” “the,” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

The term “comprise”, including any variation thereof, is intended to beopen-ended and means “include, but not limited to,” unless otherwisespecifically indicated to the contrary.

When a set of possibilities or list of items is given herein with an“or” before the last item, any one of the listed items or any suitablecombination of two or more of the listed items may be selected and used.

The above described embodiments are intended to be illustrative only.Modifications are possible, such as modifications of form, arrangementof parts, details and order of operation. The examples detailed hereinare not intended to be limiting of the invention. Rather, the inventionis defined by the claims.

1. An apparatus for operating a mold having a cavity assembly and a moldcore that cooperatively define a mold for molding of plastic articles,comprising: a clamping assembly operable to move cavity plates of thecavity assembly relative to each other along a cavity clamping axis,between a closed position in which said cavity plates abut in clampedcontact, and an open position in which the cavity plates are separatedfor removal of a molded article; a core clamping assembly comprising anactuator operable to move said mold core relative to the cavity assemblyalong a core clamping axis between a closed position in which said moldcore is interposed between said cavity plates to define said mold, and aremoval position in which said mold core is retracted for removal of amolded article.
 2. The apparatus of claim 1, wherein said core clampingaxis is perpendicular to said cavity clamping axis.
 3. The apparatus ofclaim 1, wherein said actuator is operable to apply a force along saidcore clamping axis to urge said mold core towards said cavity platesduring molding.
 4. The apparatus of claim 3, wherein said force is apreload force for resisting pressure from molding material in said mold.5. The apparatus of claim 1, wherein said actuator is operable towithdraw said mold core from a molded article along said core clampingaxis.
 6. The apparatus of claim 5, wherein said core clamping assemblycomprises a retainer for holding a molded article while said mold coreis withdrawn.
 7. The apparatus of claim 1, wherein said actuatorcomprises a rotary crank and a link assembly for causing a reciprocatingmotion.
 8. The apparatus of claim 6, wherein said link assemblycomprises an eccentric rotor.
 9. The apparatus of claim 1, wherein saidapparatus is for injection molding.
 10. The apparatus of claim 1,comprising an injection orifice for receiving a flow of molding materialalong said core clamping axis.
 11. The apparatus of claim 10, whereinsaid core clamping axis is vertical.
 12. The apparatus of claim 10,wherein said injection orifice mates to a vessel for receiving moldingmaterial from said vessel.
 13. The apparatus of claim 1, wherein saidclamping assembly is operable to move both of said first and secondcavity plates towards and away from one another. 14.-40. (canceled) 41.An apparatus for operating a mold having a cavity and a mold core thatcooperatively define a mold for molding of plastic articles, comprising:a clamping assembly operable to move mold plates relative to each otherbetween a closed position in which said plates abut in clamped contact,and an open position in which the plates are separated; a core actuatoroperable to move said mold core relative to said plates along a coreaxis between a closed position in which said mold core is interposedbetween said plates, a preload position, in which said mold core iscompressed from said closed position towards said plates, and a removalposition in which said mold core is retracted for removal of a moldedarticle.
 42. The apparatus of claim 41, comprising a spring loadassembly for supporting said mold against said plates, wherein movementof said mold core from said closed position to said preload positioncompresses said spring load assembly.
 43. The apparatus of claim 41,wherein said mold core comprises an inner core and an outer corepositioned around said outer core, wherein said actuator is operable tomove one of said inner core and said outer core relative to the other ofsaid inner core and said outer core along said core axis.
 44. Theapparatus of claim 43, wherein said actuator is operable to withdrawsaid inner core relative to said outer core in said removal position, todislodge a molded part from said inner core.
 45. The apparatus of claim41, wherein said actuator is connected to said mold core with releasablecouplings.
 46. The apparatus of claim 41, wherein said actuator ismounted to a platen of said clamping assembly.
 47. The apparatus ofclaim 46, comprising a slotted link connecting said actuator to saidmold core.
 48. The apparatus of claim 41, wherein said core axis isperpendicular to a clamping axis of said clamping assembly.
 49. Theapparatus of claim 41, wherein said core axis is vertical.
 50. Theapparatus of claim 41, wherein said apparatus is for injection molding.51.-60. (canceled)